Professional Documents
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System Manual
English
PureBallast: Ballast Water Table of Contents
Treatment System
Safety 1
System Description 2
Printed 2016
Alfa Laval reserves the right to make changes at any time without prior notice.
Any comments regarding possible errors and omissions or suggestions for improvement of this
publication would be gratefully appreciated.
Copies of this publication can be ordered from your local AlfaLaval company.
Published by: : Alfa Laval Tumba AB
E-147 80 Tumba, Schweden
Telefon: +46 8 530 650 00
Telefax: +46 8 530 310 40
2 Safety information 7
2.1 General safety information 7
2.2 Specific safety information 7
2.3 Personnel requirements 9
2.4 Warning signs used in the manual 9
3 Environmental issues 11
3.1 Unpacking 11
3.2 Other materials 11
3
1 Introduction
This chapter contains general safety and environmental information, personnel requirements and
explanations of symbols used for the PureBallast system.
This section contains safety information. This information must be read and understood before the
system is installed, operated and maintained.
The PureBallast system is not EX proofed and must not be installed in areas where an
explosive atmosphere may occur.
Use the equipment only for the purpose and parameter range specified by Alfa Laval.
Use only Alfa Laval genuine spare parts.
Always read and follow the documentation that is included in shipment of components and
spare parts regarding handling, safety and disposal.
Mobile cell phones must not be switched on within an area of 1 meter from an open cabinet door.
Before installation, read applicable sections in chapter 6. Installation instruction and drawings.
Before operation, read the Preparations and conditions section for applicable instructions in
chapter 3. Operating instructions and control system description.
2.2 Specific safety information
The following safety information apply for the areas and components below. This information is also
stated in the Preparations and conditions section for applicable instructions.
Before maintenance, read the Preparations and conditions section for applicable instructions in
chapter 7. Service manual. Essential safety information is stated before instruction to routines
that might involve any danger.
Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8.
Components must be lifted using correct lifting tools (such as a fork-lift truck, a crane) and tackle
with a load capacity greater than the weight of the component. See the Technical data section
on page for information about weight. Any complementary lifting instructions must be followed.
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
AOT reactor safety items
UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.
Before installation, check that the UV lamps and quartz sleeves are not broken.
Depressurize reactors and allow equipment to cool down completely before disassembling. Hot
water may escape from the reactor when removing the drain plug.
Never handle UV lamps before they are completely cooled down. A hot UV lamp is under
high internal pressure, and the risk of bursting exists. A hot lamp could also cause a burn
if it is touched.
The reactor must not be under pressure when dismounting the UV lamps.
UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the reactor with end caps properly closed.
UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used lamps UV can be handled and disposed of in the same
way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally
been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe
(or use pure sulphure to bind the mercury for easy collection).
Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.
Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.
Operation and/or manual start of the UV lamps is only allowed when there is water in the reactor
(indicated by level switch LS201-29), and the water temperature is below 60 C. Improper
operation could seriously damage the equipment and injure personnel.
Manual operation of LPS, may only be performed after cable connection. If not hazardous
situation may arise which, if not avoided, will result in death or serious injury.
Before maintenance of the LDC: Switch off the PureBallast system and disconnect it from the
power supply. The LDC contains a fan, which can cause injury if in operation.
Flow meter safety items
Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Valve safety items
Actuators must not be pressurized at any time during installation as it may result in injury.
Lock valve in closed position before maintenance.
CIP safety items
CIP liquid: Risk for eye and skin irritation. Avoid contact with eyes and wear protective
gloves. Follow general rules when handling of cleaning agents regarding ventilation, personal
protection etc.
Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
Always wear protective eye glasses and gloves while working on the pump.
See Safety data sheet / CIP liquid in chapter 6.
Ancillary component safety items
Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
Temperature switch, temperature transmitter and level switch. The external surface may be hot.
Care must be taken to avoid possible burns.
2.3 Personnel requirements
The PureBallast system must be operated, installed, maintained and repaired by persons trained for
respective type of work. All persons using and working with the system must know the emergency
stopping procedures.
Personnel installing, maintaining or repairing components must be of one of the following categories:
NGE R
! DA
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
NG
WARNI
!
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
ON
CAUTI
!
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
NOTE
NOTE indicates a potentially hazardous situation which, if not avoided, may result in property damage.
This section contains general rules regarding environmental issues. However, local rules and
regulations should be consulted for detailed handling of each material.
3.1 Unpacking
Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused, recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed waste incineration plant.
Metal straps should be sent for material recycling.
3.2 Other materials
Rubber and plastics should be burnt at a licensed waste incineration plant. If not available they
should be disposed to a suitable licensed land fill site.
Metal parts should be sent to a licensed handler for material recycling.
Seal rings should be disposed of in a licensed land fill site. Check the local regulations.
Worn out or defected electronic components should be sent to a licensed handler for material
recycling.
The operator panel contain the following components with substances that might be hazardous
to health and the environment: lithium battery, electrolytic capacitor and display. They shall
be recycled according to local regulations.
Used lithium batteries from the control unit are considered hazardous waste and should be
disposed of accordingly.
Used UV lamps can be handled and disposed of in the same way as fluorescent lamps. Please
refer to national regulations.
Used quarts sleeves should be disposed of as ordinary glass.
2 Process overview 9
2.1 Start-up 10
2.2 Ballasting 11
2.2.1 Power optimization 11
2.2.2 Backflush 12
2.2.3 Ballast after-treatment (CIP) 13
2.3 Deballasting 14
2.3.1 Deballast after-treatment (CIP) 14
3.3 Filter 22
3.3.1 Filter working principle 22
3.3.2 Filter description 22
3.3.3 Backflushing for different dirt loads 25
3
3.6 Main valves 31
3.7 Flow meter 32
3.8 Pressure monitoring device 32
3.9 Sampling devices 32
4
1 Introduction
This contains general information about the PureBallast system and its components.
Not in illustration:
The UV lamps are powered by the LDC (via LPSs, lamp power supplies). The AOT reactor has
one dedicated LDC.
Flow is monitored by the flow meter and regulated by the control valve. The control valve also
regulates pressure during backflushing of the filter.
The AOT reactors are cleaned using the CIP (cleaning-in-place) module, which first rinse the AOT
reactor with fresh water, and then circulates CIP liquid through the AOT. At the end of the process
the AOT reactor and the filter (filter preservation) is filled with fresh water from the CIP.
The complete system and ongoing processes is controlled and monitored from the control cabinet.
Control can also be performed from remote control panels and the ships ISCS, via the remote
interface.
The bypass valve makes it possible to bypass the entire system, for example to secure ballast
operation if the system is not functioning. The valve is controlled from the ISCS (integrated ship
control system).
1.3 Abbreviations
The table below is a list of abbreviations used in this manual.
Abbreviation Explanation
AOT reactor The main component, where the water is treated using advanced
oxidation technology
Abbreviation Explanation
EX Explosion-proof
UV Ultra violet
This section gives an overview of the main processes performed by PureBallast. In the flow chart
illustrations, involved pipes are marked in bold.
2.1 Start-up
Ballasting and deballasting begins with a start-up phase. There must be available power for
the system. If power management is integrated, this will be confirmed automatically. If power
management is not integrated, this is confirmed manually.
During start-up, the UV lamps are warmed up for 90 seconds. Cooling water is pumped through the
AOT reactor to secure that the UV lamps are not overheated. The temperature transmitter and
level switch secure that there is water in the AOT reactor and that the UV lamps are sufficiently
cooled. If not, an alarm is issued and the system is shut down.
2 Startup Filtrex
2.2 Ballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The ballast water is pumped from the sea chest to the filter, that removes larger particles and
organisms. This also reduces the amount of sediment build-up in the ballast water tanks. The
organisms and sediments caught in the filter is flushed overboard via regular filter backflush
operations. The water is finally led to the AOT reactor, which produces radicals and UV light
that breaks down and neutralize the organisms.
The UV lamps are regulated individual on all AOT reactors between 50 % and 100 % of full effect.
During start-up and the first two minutes of ballast/deballast, the UV lamps are lit to 100 % to
ensure treatment before values from the UV sensor are stable.
Pause: UV lamps are dimmed to 50 % during pause and lit to 100 % for two minutes when
process is resumed.
Stop: UV lamps are lit to 100 % for 10 seconds before they are stopped. This will prolong
the life of the lamps.
Low UV intensity: See Actions at low UV intensity below.
Broken UV lamps: See Operation with broken UV lamp below.
If the UV intensity falls below minimum (defined in parameter p221) for one AOT reactor, a warning
is issued, but process continues. When UV intensity falls below 484, defined in the type certificate,
a new warning is issued and a log is written to the event log. The operation continues but does
not fullfill the type approval certificate. However, the flow is decreased so that the treatment shall
correspond to the type approval requirements. The operator will have do decide to continue or
stop the operation.
If a UV lamp breakes, the ongoing process continues but does not fullfill the type approval
certificate. The flow is decreased to 80 % of current flow and the UV lamps are lit to 100 %. These
actions are taken so that the treatment shall correspond to the type approval requirements. A
warning is issued and a log is written to the event log.
2.2.2 Backflush
To keep the filter clean, it is automatically backflushed. The backflush is performed during ongoing
process without interrupting the ballasting process. When a ballast operation is stopped, a
backflush is performed before the system comes to a full stop. The water used for backflushing is
returned to the sea directly at the ballasting site.
2 BackflushFiltrex
Filter backflush
We recommend that a CIP process is performed within the same ecological zone or in international
waters (200 nautical miles from the base line). This will avoid untreated water from the AOT and
the filter to enter a different ecolodgical zone.
The AOT reactors are cleaned one at a time. First, the AOT reactor is rinsed with fresh water. Then
the cleaning-in-place (CIP) module circulates a biodegradable solution through the AOT reactor to
remove seawater scaling. After the cleaning is finished, the AOT reactor is filled with fresh water to
preserve the filter is and prevent scaling, algae growth etc. Then the system continues with the
same procedure for the next AOT reactor. Finally, the filter is filled with fresh water to prevent
scaling and algea growth. The cleaning liquid is reused between the cleaning operations.
2 CIP Filtrex
2.3 Deballasting
After the start-up, when the lamps are ready, the operator is requested to start the ballast pump.
The water passes through the AOT reactor, but the the filter is bypassed since the water has
already been filtered during ballasting. The reason for treating the water a second time during
deballasting is to secure that the treatment is fully effective. The minor part of the organisms, which
were only injured during ballast, will be rendered totally harmless during the deballast.
The process flow and power optimization are controlled in the same way as during ballasting.
2 DeballastFiltrex
Deballasting
After the start-up, when the lamps are ready, the operator is requested to start a stripping pump.
Pump used can either be a dedicated stripping pump or a ballast water pump. The process flow
and power optimization are controlled in the same way as during deballasting. Number of AOT
reactors used during stripping is set in a parameter, to make sure that the flow is as close as
possible to the flow from the stripping pump/eductor.
If a stripping eductor (not part of Alfa Lavals scope of supply) is used it must be installed before the
PureBallast system. Minium flow for deballast water includes the driving water.
Also, the water used in the stripping process, must be filtered from particles larger than
approximately 5 mm. The sieve is not part of Alfa Lavals scope of supply. Procedures to dispose
of sediments from the sieve must be included in the vessels ballast water management plan. See
also chapter 3. Operating instructions and control system description, section Stripping.
2 StrippingFiltrex
Stripping
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. In case untreated water is pumped to a ballast tank, this water shall
be discharged on open sea (according to regulations) and exchanged for treated water. Note that
full treatment requires treatment both during ballast and deballast.
The procedures concerning emergency and malfunction of the ballast water treatment system
should be implemented in the ships Ballast water management plan.
This section gives an introduction to the most important PureBallast system components and
their functions in the system.
2 10_2_1_1 Cell
1. Radical
2. Cell membrane
There are no chemical substances added to the process, and there are no toxic residuals created.
Since the water is not affected chemically there are no environmental impact, and the process does
not influence corrosion in any way.
The UV lamps get very warm, so they must be cooled whenever they are lit. To secure that there
is water in the reactor when the lamps are lit, each reactor is equipped with a level switch. The
level switch also secures that enough CIP liquid is pumped into the reactor during the CIP process.
To secure that the lamps are adequately cooled by the ballast water, each AOT reactor has
a threefold heat protection:
The temperature transmittre sends information to the control systemat. The AOT reactor is
shut down at 60 C.
The temperature transmittre sends information to a safety relay in the LDC. The AOT reactor is
shut down at 62.5 C.
The temperature switch automatically shuts down the AOT reactor at 65 C.
A UV sensor monitors the UV lamp efficiency in relation to the water transmittance inside the AOT
reactor. Based on this input, the power to the UV lamps are regulated between 50 and 100 % of full
capacity. The UV lamps will be dimmed to lowest possible level, where they are still effective.
Note, that the lamps are always lit with full effect during start-up and the first two minutes of full
ballast to secure full efficiency independent of transmittance. The lamps are also turned up to full
effect for 10 seconds before stop and normal shut down. This method will prolong the UV lamp life
time.
The illustration below show the main components for the AOT reactor.
AOT reactor
The humidity in the cabinet is monitored by a liquid sensor. If a leakage from the heat exchanger
is detected, a warning is issued, the reactor is shut down and the cooling water inlet valve to
the LDC is shut.
The LDC can be placed up to 150 meters (cable length) from the AOT reactor. The main breaker
cut the power to the LDC and the AOT reactor.
2 LDC
1. Fan
2. Heat exchanger
3. Lamp power supplies (LPS)
4. Fuses
5. Cooling water inlet and outlet
6. Main breaker
7. Status lights and reset button
3.3 Filter
2 FilterFiltrex
1. Geared motor
2. Water outlet
3. Fresh water inlet
4. Backlflush outlet
5. Drain plug
6. Water inlet
7. Pressure transmitter, inlet
8. Pressure transmitter, outlet
9. Junction box
To secure efficient filtration, the filter performs a self-rinsing backflush operation at time set intervals
or when triggered by indication of dirt in the filter. Pressure drop over the filter is monitored by
pressure transmitters on the filter inlet and outlet. Dirt is detected by an increased differential
pressure drop caused by particles in the filter. When the differential pressure reaches a parameter
set value, an automatic backflush operation starts.
The backflushing does not interrupt the filtration process, since only a part of the filter element area
is cleaned. The areasa that are not cleanes at a specific time continues the filtration of the ballast
water. It is also possible to start backflush manually from the control system.
Step 1: Filtration
The water enters from the inlet flange (A) and flows through a
pre-filter and then through the filter element (1) from the inside to
the outside. The filtered dirt is trapped on the inside of the filter
element. The filtered water passes the chamber (D) and out from
the filter through the outlet flange (B) and is lead to the AOT reactor.
A. Inlet
B. Outlet
D. Chamber
1. filter element
2. Motor
3. Nozzle (standing still during filtration)
2 FilterFiltrationFtrx
Step 2: Backflush
At backflush, the motor (2) starts to drives the nozzle (3). At the
same time, the backflush valve (6) opens.
The nozzle rotates inside the filter element. The dirt on the inside
of the filter element (1) is cleaned by a high-efficacy backflush flow
in front of the nozzle. The backflush flow uses filtered water from
the chamber (D) to clean the filter from the outside to the inside.
The water, together with the dirt, is lead via the nozzle through the
duct (5) and out via the backflush valve (6).
All areas of the filter element that is not in front of the nozzle are
filtering the water as in step 1: The water flows from the inlet (A)
through the filter element and out through the outlet (B).
A. Inlet 2 FilterBackflushFtrx
B. Outlet
D. Chamber
1. filter element
2. Motor
3. Nozzle seen from the side (rotating during backflush)
6. Backflush valve
In water with low dirt load, the backflush cycle is started by the time trigger (default: every 30
minutes). As long as the pressure is below the differential pressure trigger (0.50 bar), there is no
need for the pressure triggered backflush. See examples below.
6 Dirtload1 Filtrex
6 Dirtload2 Filtrex
In more dirty waters the backflush cycle will be triggered when pfilter reaches 0.5 bar, which indicates
dirt in the filter.
After each backflush, the backflush timer is reset. The filter will be backflushed again after 30
minutes or when pfilterreaches 0.380.5 bar, whichever comes first.
In the example below, three backflushes are triggered due to high differential pressure over the filter.
After that, there is not so much dirt build up, so the next backflush is performed after 30 minutes.
6 Dirtload3 Filtrex
In conditions with heavy dirt load, the system can perform continuous backflushes to keep the filter
clean. If the filter preforms one backflush, and the differential pressure trigger a new backflush
within a parameter set time, the filter will perform continuous backflushes for a parameter set time
to clean the filter thoroughly. After the continuous backflush time, a check is made to make sure
that the differential pressure is below 80 % of the backflush trigger pressure. If not, the backflush
continues until this is true.
Also, the 0.380.5 limit might be exceeded. In this case the self rinsing cycle will run continuously
until the problem is solved and the pressure has returned below 0.380.5 bar. It is OK that the flow
momentarily fluctuates in an irregular curve, but it is important that the curve stabilizes.
In the example below, a series of backflushes are performed (approx. every 4 minute). After that
the pressure rises above 0.380.5 where the filter is backflushed constantly. After that, the normal
control is resumed, where the filter backflush is triggered by pressure (2 times) or by time (last
backflush in the example.
6 Dirtload4 Filtrex
Over time, the element will undergo a long term build-up of particles that are not removed by
backflushing. One effect of this is that normal pressure will increase over time. Therefore, the
maintenance schedule state that the element shall be inspected and manually cleaned once a year.
The extent of the long term dirt build-up is dependent on the water conditions. In the great majority
of cases this will not cause any problems cleaning once a year is enough. But in exceptional
cases (vessels trading very muddy waters) it might be necessary to clean the filter element more
often. If the pressure triggered backflushing is performed with short intervals, we suggest that the
filter element is manually cleaned more often than once year.
During a cleaning cycle, the CIP module rinse the reactor with fresh water and circulates a CIP
liquid through the AOT reactor. The low-pH CIP liquid removes scaling, calcium chlorides, metal ion
build-up and chemical fouling on the lamps quartz glass sleeves. After finished cycle, the liquid
is returned to the CIP module tank; the CIP liquid is reusable for a great number of cycles. The
sequence is finalized by filling the AOT reactor with fresh water. A backflow preventer secures
that no CIP liquid is mixed with the fresh water.
To secure that there is enough CIP liquid for the process, the level switch in the reactor indicates
when it is filled with CIP liquid. To prevent intrusion of water in the fresh water system, a backflow
preventer is used in the CIP module.
Pump P320-1 circulates the CIP liquid in the AOT reactor and fills it with fresh water.
Pump P321-5 drains water (sea and fresh water) overboard from the reactor, via the drain line.
2 CIP module
CIP module
1. Deaeration valve
2. Valve block
3. Regulator
4. Pump (CIP liquid)
5. Backflow preventer
6. Pump (reactor drain)
7. Tank for CIP liquid
The control cabinet functions as a signle point of contact for signal cables to and from the vessel.
Examples of integration: Remote interface integration and power management system (PMS).
Remote interface will allow control of PureBallast from the vessels ISCS and PMS integration will
allow automatic verification that there is enough power to run an operation. If not integrated, the
operator must verify this manually. Also integration with other external components (not part of Alfa
Lavals scope of supply), such as GPS or booster pumps, are done to the control cabinet.
2 CC
Control cabinetpanel.
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest logs. Logged
information can be exported to a USB memory stick.
There are three alternative ways to monitor and control PureBallast: Main panel, remote control
panel (optional) and remote interface (optional).
If two PureBallast systems are installed on a vessel, two control systems are needed.
2 CC
2 RCP
Note that Alfa Laval does not supply the graphical user interface to handle PureBallast in the
ISCS, only the means to enable the integration.
2 RI
PureBallast control systems main control panel integrated with the ISCS. The interface is only an example.
Inlet valves: The inlet valves directs the water flow from the vessels ballast water system into
the PureBallast system. Different valves are used during ballast and deballast.
- System and filter inlet valve (2013): Inlet valve to PureBallast during ballast. The valve
directs the water flow through the PureBallast filter.
- Filter outlet valve (V20132): The valve directs the water flow from the filter to the AOT
reactor during ballast.
- Inlet valve (2019): Inlet valve to PureBallast during deballast. The valve directs the water
to PureBallast, but bypass the filter, since the water was filtered during ballasting.
Control valve (V2018): The valve have the following functions:
- Automatic regulation to maintain flow during operation so it does not exceed selected
certified maximum flow. Regulation is based on input from the flow meter.
- Automatic regulation to maintain pressure needed to perform backflush of the filter.
Regulation is based on input from the pressure transmitter.
- Outlet valve from the PureBallast system to the vessels ballast water system after treatment.
PureBallast bypass valve (V21231): Makes it possible to completely bypass the PureBallast
system. The valve is solely operated from the ISCS, but the valve positioning is (and must be)
indicated in the PureBallast control system. When PureBallast is bypassed, an event is written
to the event log. The valve is equiped with a handwheel for manual operation. The component
is optional to be included in Alfa Lavals scope of supply.
Cooling water inlet valve (V403-35): Supplies cooling water to the reactor to secure cooling of
the lamps and prevent overheating during start-up.
3.7 Flow meter
The flow meter (FIT2011) monitors the process-flow during operation. It has two main functions:
It monitor that the flow within the PureBallast system does not exceed its certified flow. If the
certified flow is exceeded a warning is issued.
Via the flow transmitter, mounted on the flow meter, it sends valuable data to the PureBallast
control system, where it is displayed. Example of information: Current flow and data about
total amount of treated ballast water.
The flow meter consists of two main parts: A flow sensor, which is a pipe with four electrodes
detecting the flow. On top of the pipe, there is a terminal box, where the flow transmitter is
mounted. The flow transmitter monitors the flow and transmits the information to the PureBallast
control system.
Pressure transmitter(PT201-16): Send current pressure information to the control system. The
control system use the information to take actions accordingly, for example issue warnings, shut
down the system or adjusting the control valve to obtain optimal pressure during filter backflush.
Pressure gauge (PI201-18): Analogue displayed of current pressure.
Needle valve (V201-15): Enables connection of external instruments for calibration.
Safety valve (RV201): Relief of over pressure.
3.9 Sampling devices
The two sampling devices (Q201.1 and Q201.2) make it possible to take water samples to test the
water. One sampling device is installed before the water is treated and one after the water is
treated. This enables comparative tests of treated and untreated water. The component is optional
to be included in Alfa Lavals scope of supply.
3
3.8 Page 3.2 Trend (1 h) 37
3.9 Page 3.3 Trend (1 h) - TT201-33 37
3.10 Page 3.4 Trend (1 h) - TT401-2 37
3.11 Page 3.5 Trend (1 h) - Power
optimization 37
3.12 Page 4.1 System info 38
3.13 Page 4.2 PLC controller I/O 41
3.14 Page 4.3 Operation timers 42
3.15 Page 4.4 Operation timers AOT 43
3.16 Page 4.5 Remote interface 1 44
3.17 Page 4.6 Remote interface 2 45
3.18 Page 4.7 Log box 1 46
3.19 Page 4.9 LPS overview 48
3.20 Page 5.15.7 Parameter pages 50
3.21 Popup windows 50
3.21.1 AOT popup 50
3.21.2 Filter popup 56
4
4 Operating instructions 59
4.1 Log in 59
4.2 Perform ballast 59
4.3 Perform deballast 61
4.4 Perform tank stripping 62
4.5 Pause ballast / deballast / stripping 63
4.6 Heel (internal transfer) 64
4.7 Backflush filter manually 65
4.8 CIP clean AOT reactor after ballast /
deballast / stripping 65
4.9 Attend to alarms 66
4.10 Shut down and deactivate system 68
4.11 Reset system after shut down 69
4.12 Operate components manually 70
4.13 Operate UV lamps manually 71
4.14 Set ship specific component ID 73
4.15 Export control system event log files 74
4.16 Backup control system settings 76
4.17 Restore control system settings 76
4.18 Set control panel IP address 77
4.19 Set remote control panel
communication 78
4.20 Set remote interface communication 80
4.21 Test remote interface communication 80
4.22 Simulate power request 82
4.23 Set default parameters 83
4.24 Update control system softwares 83
4.25 Calibrate the control panels touch
screen sensibility 83
4.26 PID calibrate system 84
4.26.1 Calibrate pressure controlled regulation 84
5
5 List of logged information 87
5.1 Event log 87
6
1 Introduction
The control system is used to operate and monitor the PureBallast system. It also contains
functions for setting parameters, saving log files etc.
This chapter describes the control system. It includes general description of the control system
pages, step-by-step instructions and a process description with detailed information about the
components (valves, motors, pumps etc) involved in each step of respective process.
The following control system related information is given in other chapters of the manual:
- When overboard valves are requested to be opened/closed, this means that all valves
leading the flow from the PureBallast via one of the following pipes must be opened/closed:
201, 309 and 403 and 404. During CIP process, 460.1 must be opened.
The input flow to the PureBallast system shall be as close as possible to the flow that has been
selected for an operation. This will reduce the stress and wear of the control valve.
1.1.1 Stripping
Stripping can be performed to empty the ballast tanks. The first time a ballast tank is stripped,
PureBallast must be bypassed.
The stripping process is basically the same as a ballast process with onedifference: A stripping
eductor or a stripping pump should be used to secure enough flow in the system.
If external component signal for heeling mode is integrated between PureBallast and the vessels
ISCS, ongoing process will be paused and resumed automatically. The user is notified of started
and stopped heeling via warnings, and the event is logged.
If no external signal is integrated, the ongoing process must be paused manually. During pause,
cooling water is flushed through the AOT to cool the UV lamps. After completed heeling, the
operator must resume the paused process.
PureBallast is equipped with a bypass valve. The valve can be used in case of emergency to secure
the ship, by allowing ballast water operations (ballast, deballast and internal transfers) without
involving the ballast water treatment system. The valve is controlled by the ISCS, not PureBallasts
control system, but all valve activities are logged in the event log. Such valve is required by the
International convention for the control and management of ships ballast water and sediments 2004.
If the system malfunction in connection with general cargo operation, ballast and deballast
operations should be avoided. Note that the system requires treatment both during ballast and
deballast.
If untreated water is pumped to a ballast tank, this water shall primarily be discharged to a reception
facility. When this is not possible, other discharge possibilities must be agreed with the port state
responsible for the waters where the ship is sailing and most importantly be agreed with the flag
state administration of the ship; the procedures concerning emergency and malfunction of the
ballast water treatment system should be implemented in the ships Ballast Water Management
Plan which must be approved by the flag state administration.
However, in some cases there is a risk that treated ballast water is contaminated by untreated
water, i.e. there are living organisms in the water. Those risks are described below, together
with suggested measures to solve the problem. Consider to include solutions in the ballast water
management plan.
Even a very small amount of water, a few hundred liters, can contaminate a ballast tank and cause
non compliance during a compliance test. It is therefore important that PureBallast is always
used when water is taken in and discharged.
If ballast/deballast is not performed in a correct way, there is a risk that there will be not fully treated
water in the pipes and the tanks.
To solve the problem: Make a complete exchange of the ballast water in the tanks by using
PureBallast at deballast and ballast at a location where ballast water exchange is accepted. Also
makes sure that dead end pipes are flushed during the process to get rid of all potentially untreated
water.
In PureBallast, a deballast process is run with the vessels ballast valves positioned so that the
pump takes water from a ballast water tank with treated water and
the water flow is directed either overboard or to another ballast tank.
Run the process for enough time so all water in the piping is treated. Time for this depends on pipe
size and length on board.
This section describes different login levels, overview of the system interface and how to navigate
and operate the control system.
Guest N/A Default mode of control system. This level is not password protected.
AlfaLaval N/A Full access. Password only available for Alfa Laval personnel.
The information below is only valid if remote control panels and/or remote interface is installed.
To switch command from one panel to another, you log in to the new panel. This is only possible by
using the same or higher login level as used in the active control panel. When control is about to be
changed from one panel to another, the following will happen:
The inactive control panel will display a popup message informing that another control panel is
active (some one else is logged in). The popup gives the alternative to cancel or to continue. If
continue is chosen, control is swithced from the first panel to the new panel.
The active panel will display a popup message informing that another the panel is inactive
and that control is taken by another panel.
On each control panel it is possible to see which panel that is active and which login level that is
used. A panel alias can be entered to clarify where the panel is installed, for example pump room,
bridge etc. See instruction Set control panel IP address on page 77. This information is visible in
the upper right corner of the system according to syntax: login level@control panel.
3 ActivePanel
It is only possible to switch command between control panel and ISCS from a PureBallast control
panel. This is done by using the Local and Remote buttons, when logged in as Operator or higher.
Control status (local or remote) is indicated by a green light under the button that corresponds to
the system currently in command. In the ISCS, control status can be indicated by using the status
signal dedicated to this. It is recommended that this signal is implemented in the ISCS.
When remote interface is activated, PureBallast can only be controlled from the ISCS. It possible
to access the same pages and perform the same operations from the ISCS as for login level
Operator (to the extent that the systems are integrated. However, the following two tasks can only
be performed from a (any) control panel: Set parameters and switch control between control
panel(s) and ISCS.
When remote interface is activated, the panel(s) can only be used to monitor the system, export log
files and switch control between PureBallast control panel(s) and ISCS.
The PureBallast system manual does not give any information about how to run PureBallast from
the remote interface. This is due to the fact that the remote interface is custom-made. Please refer
to the vessel specific manual. For more info, see list of fiffiga saker
PureBallast can be operated from ISCS when the conditions below are met:
The remote interface must be correctly installed, according to Remote interface implementation
guide.
Remote interface must be activated (parameter p132) and communication settings must be
correct (parameter p700 p704).
The Test mode button must be deactivated (no checkmark on the button) in control system
page 4.5 Remote interface 1.
Remote control must be activated. Check that the green lamp is lit under the Remote button
on the control panel. If not, press the button. The system must be in Standby mode to toggle
between local and remote operation.
Operation
Heartbeat is updating. See that address 06 and 77 are updating in control system page 4.5
Remote interface 1.
There must be no active alarms for the AOT reactors to be used during operation. Always check
the alarm list (page 2.1 Alarm list in the control system) before operation.
AOT reactor must be in standby mode.
The control system use a touch screen, where you tap the screen to click or drag objects. Do not
use sharp objects to touch the screen. When the screen is left idle it will go to screensaving mode.
Time is set in page 4.1 System info. The screen is activated again by touching it once. The touch
will not activate any button that might be placed where you touch.
The illustration below shows the main areas and function buttons on the screen.
3 1.1 Filtrex
Tabs: The top and side tabs are used to choose which page to display in the screen. Pages are
referred to as a number and a name, for example 2.1 Alarm list. The first number refers to selected
top tab, counted from left to right. The second number refers to selected side tab, counted from top
to bottom. Selected tabs are indicated by a white color.
Top tabs: Contain the main function areas of the control system: Overview, alarm lists, trend
indication, system information and parameters.
Side tabs: Contain sub pages for the area selected in the top tab. Available side tabs change
depending on which function area that have been selected in the top tab.
Popup windows: Are used to display or enter detailed information. It is possible to move a popup
by touching the name bar and drag it. A popup is closed either by touching confirming entered
information by touching a function button (OK, Confirm, etc.) or the X icon in the top right corner
(data is not saved).
Data entry fields: A white field indicates that it is possible to enter data. When the field is touched,
a keyboard is displayed, which is used to enter information. Enter data is confirmed by touching the
Enter button. To close the keyboard without saving data, touch the Esc button.
Tables: Individual table rows, for example an alarm, can be selected by pressing them. Column
widths can be adjusted. Press the column border in the head area and hold the finger on the screen.
Function buttons: Function buttons are used for main processes and control of the system. They
are placed att the bottom of the screenare and are always visible, but only available when colored
dark blue. Some buttons are dependent on parameters. For example, the Remote and Local
buttons are only visible if remote interface is activated.
Status indication Button color: The buttons appear in different colors, indicating status:
Blue The function is enabled.
Grey The function is disabled, for example if higher login level is required for the
function.
Status indication Button light: After a function button is pressed, a light under the button is lit
to indicate status for the activated function:
Yellow Command will be processed when possible in the data work flow.
Button Description
Button Description
3 CIPbut
Activate operation from control panels, instead of remote interface (if option
is used). The button is only enabled in standby mode.
3 LocalButton
3 RemoteBut
Sets the control system in manual mode, which enables manual operation
of the system and its components. When activated, the light flashes yellow.
The button is displayed for login level Advanced operator or higher. For
3 EnableManual detailed information see Manual mode on page 107.
3 WhipeBut
Activate night light for the panel. Night light makes the panel less bright.
Toggles between night light and day light.
3 NightBut Degree of brightness, is set in the Night light level field in page 4.1 System
info.
Alarms and warnings for components are displayed in the flow chart and popups:
Active alarm.
3 Alarm
Active warning.
3 Warning
This section describes the pages used for operation. Note that this section does not cover the
parameter pages. Please refer to chapter 4. Parameters.
The main areas are the Status box and the Flow chart.
3 1.1 Filtrex
Process and sub process Process: Ongoing process. Can be standby, ballast, deballast
and CIP.
Time Remaining time for the ongoing sub process in the upper right
corner.
Processed volume (m3) Amount of water processed during ongoing process. Value
remain until next process is started.
Certified flow (m3/h) Certified flow (m3/h) selected for operation. The information is
updated after the warm up time has passed and a AOT reactor
is used for process. This is also the flow the system is aiming
to keep.
Current flow (m3/h) Water flow in the system, indicated by flow transmitter FIT201-1.
The system aims for the selected flow minus parameter p111
Undershoot certified flow, which can be set as a safety margin.
Flow selection Flow (m3/h) selected for operation.
Ballast pump Status indication for balast water pump (not part of Alfa Lavals
scope of supply).
Status indication
Green = Feed back that pump is running, either via hard wired
feedback, remote interface or the confirmation popup.
Overboard valve(s) Status indication for overboard valve(s), and other relevant
valves for the process (not part of Alfa Lavals scope of supply).
Status indication
Green = Feed back that valve is open, either via hard wired
feedback, remote interface or the confirmation popup.
Grey = Closed.
Relevant information regarding ongoing process and component status can be monitored directly
in the flow chart. Flow in pipes is indicated by coloring of the pipes and component status are
displayed by color indications. Pressure, flow and control valve opening percentage are displayed
directly on component.
Detailed information about components can be monitored in popups (by tapping the component):
AOT reactor see page 50; filter see page 56. CIP open page 1.3 CIP status, see page 25). The
popup contain status for sub components, for example valves, motors and UV lamps in the AOT
reactor.
AOT cooling water pump (P4031) is only displayed if it is used and activated in the parameter
pages.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually: If a component is pressed, a popup window is displayed from which the component
can be operated.
Status indication
Mixed colors = Mixed water, for example ballast water and fresh water.
Status information for bypass valve(s) V21231 and external bypass valves
(not part of Alfa Lavals scope of supply). These valves are operated from the
ISCS, due to safety reasons.
3 P309
3 Manual1
This page is only relevant if more than one AOT reactor is installed.
Normally, flow is handled from page 1.1 Overview, and this page is used during commissioning and
faultfinding when it is necessary to start individual AOT reactors.
The main areas of the page are the Flow selection, AOT selection and Status.
3 1.2
Elements Description
Modify button Enables active selection of individual AOT reactors. When pressed, the
buttons for respective AOT reactor turns blue and are possible to use.
AOT 1, 2, 3 button One row for respective installed AOT reactor with current status indicated
in the columns.
Status indication:
3.2.3 Status
The area displays current status for the flow:
Elements Description
Current flow Ballast water flow in the system, indicated by flow transmitter FIT201-1.
Certified flow Maximum allowed flow as set in Flow setpoint or limited by the number of
AOT reactors selected in AOT selection popup. If a smaller filter is installed,
the ballast flow can be lower than the AOT reactor capacity.
The information is updated after the warm up time has elapsed and a AOT
reactor is used for process. (Before that it is not used for treatment, and
therefore not part of the certified flow.)
3 1.3
Row Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.
Row Content
AOT Each row display CIP status for every installed AOT reactor
Filter preservation This row indicate status and time for the filter preservation process, that
starts after completed CIP. During filter preservation, the CIP fills the filter
with fresh water for preservation purpose.
Total Total estimated time for a complete CIP process including filter preservation.
Column Content
CIP error Red square: Indicates that there is an active alarm for the component.
Check alarms on page 2.1 Alarm list.
Status indication
Yellow = CIP required. During ongoing CIP process, yellow indicates that
the AOT reactor is waiting for CIP process to start.
Column Content
Estimated time Time remaining CIP time. If CIP process has not been started, total time is
displayed. During CIP process, the time is counting down continuously.
The CIP process takes about 25 minutes per AOT reactor, if default
parameters are used.
Required CIP Time before a CIP process must be performed after ballast or deballast.
countdown The time disappears when the CIP process is ready. Time is displayed for
the AOT with shortest time left to required CIP.
3 1.4
Column Content
Process and sub Process: Ongoing process. Can be standby, ballast, deballast and CIP.
process
Sub process: Sub steps of ongoing process, for example Start-up during
Ballast process.
Max power Maximum power consumption for the number of selected AOT reactors.
consumption The value is updated when a process is started.
Measured power Power consumption during process. Value calculated based on number of
consumption used AOT reactors.
Power status
Column Content
Pure Ballast always asks for power before the UV lamps are lit during ballast
or deballast start-up. When a request has been sent, the vessels power
management performs a power check before the generator is started.
The page can also be used to troubleshoot the power management system integration by sending
and checking each signal.
Buttons Content
Request Press to manually simulate request for a power step. The button is
displayed for login level Advanced operator or higher.
Set run Press to manually simulate run signal for a power step. The button is
displayed for login level Advanced operator or higher.
- A = Alarms stop the ongoing process, which can be restarted after the problem has been
attended to.
- W = Warnings are notification of a status change, request for action or a problem that must be
attended to. Warnings allow the process to continue.
For detailed information about alarms and warnings see chapter 5. Alarms and faultfinding.
3 2.1
The main areas of the page are the Alarm list and the Function buttons:
Column Content
Text Descriptive alarm text written as: Area-Alarm type AlarmID Alarmtext.
Example: AOT2 A138 Error in LDC cabinet.
Acknow- The time the alarm/warning was acknowledged. The alarm/warning remains
ledged time in the alarm list until the causing condition is resolved. For example a high
temperature alarm will remain visible, until the temperature is below the limit
value for the alarm/warning.
The table below shows status indication for alarms and warnings in the alarm list.
Button Function
Ack selected Acknowledge selected alarm (row). Press a row to indicate it, and press the
button to acknowledge it.
3 2.2
Column Content
Text Same as in Page 2.1 Alarm list.
Normal time The time the value that caused the alarm returned to normal.
3 3.1
Trends can be plotted for the following components (identified by item number) and key values:
Filter diff. pressure Bar Differential pressure over filter, indicated by pressure
transmitter 20171 and 20172.
Y axis: The scale and unit used for the Y axis is set in the Settings popup for respective component.
For details, see the Component area section below.
Settings Press the button to make settings for the components curve. Settings are
button done in a popup.
3 TrendCurveSet1Nr
1: Press (not slide) the top right button to display or hide trend curve in the
diagram. A green I indicate displayed, and a grey O indicates not displayed.
2: Press the entry field to change start and stop value for the components Y
axis scale (when this components scale setting is used).
3: Press this button to use this components scale setting in the diagram.
4. Press the entry field to enter number of decimals in the component area, or
use the - - or ++ buttons to increase or decrease.
Value Current value for the component is displayed in the gray field. (This
corresponds to the diagram.)
Buttons Content
Export long- Export trend curve history as a csv file. The file can be sent to Alfa Laval for
term trend advanced trouble shooting.
data to USB
Insert a USB memory in USB panel port on the cabinet door. Press Export
long-term data to USB button. Wait for the message Exporting database
table to disappear. The file has been downloaded to the USB memory,
in a folder named DatabaseExport.
History mode Only available for page 3.1. Press the button to display this popup:
3 TrendCurveTime
Press one time unit (year, moth, day etc) and then press or + to set time.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
See page 3.1 Trend (15 min.) for information about function, fields and buttons.
See page 3.1 Trend (15 min.) for information about function, fields and buttons. See chapter 2.
System description, section Power optimization for details.
AOT UV setpoint: The UV intensity the system is aiming to attain by increasing or decreasing
power effect to the LPS controlling the dimming of the UV lamps. The setpoint is based on
actual transmittance and is updated every 15 seconds.
UV measurement: Actual UV intensity (W/m2) measured by UV sensor QT20150. If intensity
is lower or higher than needed, the power to LPS will increase or decrease to attain setpoint
for UV intensity.
Power output: Actual LPS power to UV lamps. The power is adjusted to attain the setpoint for
UV intensity based on measured water transmittance. Output is adjusted based on input from
UV sensor QT20150. Power can be 50100 %.
3 4.1
HMI info CPU: Control panels usage of the central processor unit (CPU) in
percent of total capacity and temperature (C). The control panel will
shut down when the CPU reaches 100 C.
Used storage: PLC flash cards used storage in percent and MB.
Storage used for the event and alarm log.
iX version: N/A.
Setup button: Opens popup to set IP address for the main panel and
the remote control panels (optional). Requires login level AlfaLaval.
HMI date and time UTC Date and time: Only used if GPS with RMC protocoll is not
connected to the control system. If so, time is retrieved from the
GPS. Requires login level Advanced operator.
Set button: Set time and date for the main control panel. Remote
control panels are updated with this time within 15 minutes after
syncronization.
HMI Backlight Screen saver timeout: Defines time before the panel is set to
screen save mode. This is set individually per control panel.
Night light level: Defines percent of full light for the night light
mode. Night light is activated by the Night function button.
PLC Info CPU temperature (C): Temperature of the central processor unit
(CPU) in the PLC.
Backup and restore Settings to/from USB panel: Export and inport information to the
USB panel port on the cabinet door.
Set default button: Set all parameter values to the default values.
Requires login level Advanced operator.
Export log files Export button: Opens the Export log files popup to export (copy)
event log files and alarm list.
Remote control panels Remote control panels button: Open a popup used for setting IP
addresses for remote control panels (optional). See instruction Set
control panel IP address on page 77.
Note that this page is only intended for Alfa Lavals personnel and only visible and available for
login level AlfaLaval.
3 4.3
Row Unit
3 4.4
AOT 13: Total runtime for the UV lamps in Lap time for installed UV lamps, since
Lamps on respective AOT reactor. the counter was reset after previous
reset at UV lamp change.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.5
Test mode Activates test mode. Communication can be sent between the
ISCS and PureBallasts PLC without actually affecting the control
system (start process etc). To send information, enter desired
digits in the entry field.
For detailed information about addresses, information and format, see chapter 6. Installation
description and drawings, section Remote interface integration (optional).
3 4.6
3 4.7
Column Content
Configuration Select configuration number by entering a number or using the arrow buttons.
nr Signal status and Configuration are displayed for selected configuration
number.
Signal setting
Configuration This is the definition of which signal that should be active to constitute a
bypass/heeling. Tap the checkbox to select or unselect it.
3 4.9 Obe
Column Content
Lamp OK Status: Green = UV lamp lit and LPS is OK. Red = LPS in fault state.
Voltage fault Status: Red = Too low incoming power to the LPS.
It is possible to lock a popup, so it remains open, even if you change page. Press the pin icon to
lock and unlock the popup.
Grey = Unlocked. Blue = Locked.
3 PopLock
3 PopLockBlue
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually. If the component is pressed, a popup window is displayed from which the sub
components can be operated. Operation of UV lamps in LPS control popup requires login level
Advanced operator. LDC cooling water pump (P4011) is only displayed if it is used and activated
in the parameter pages.
AOT status: Status indication for the AOT reactor: Stopped or Started.
AOT illustration
Component Description
Grey = Off.
Yellow = Starting.
Green = Started.
Component Description
Valves For status indications, see Status indication Component color in section
Flow chart on page 21.
LDC status
Component Description
Open the LPS control popup, which enables manual operation of individual
UV lamps. Requires login level Advanced operator to see the button and
3 LPSctrlbut
manual mode open the popup. See LPS control popup and instruction
Operate UV lamps manually on page 71.
Open the LPS status popup, which gives an overview of status for UV
lamps and LPSs.
3 LPS StatusBut
Fan speed Fan rotation in percent of full effect. Fan effect is based on need for cooling.
Water temperature Temperature of incoming cooling water to the LDC cabinet indicated by
TT4011.
Heat exchanger Indicates if the valve for LDC cooling water (SV40151) is open.
valve Status indication: Green = Open. No indication = Closed.
P4011 Cooling Indicates if the LDC cooling water pump is running or not. The pump is
water pump running if the cabinet needs cooling, based on temperature.
Status indication: Green = Running. No indication = Not running.
The popup is used for to manually start the UV lamps in the AOT reactor. See instruction Operate
UV lamps manually on page 71. The popup is displayed when the LPS control button is pressed
in the AOT popup. Requires login level Advanced operator to see the button and that manual
mode is activated to open the popup.
The AOT reactor is equipped with 16 UV lamps. In each lamp drive cabinet (LDC) is 16 lamp
power supplies (LPS) that supplies power to one UV lamp each. The lamps can be operated
individually in manual mode.
NGE R
! DA
Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Improper
operation of this function could seriously damage the equipment and injure personnel.
Component Description
AOT number Information is displayed for the AOT reactor selected in the AOT number
field.
Enables manual operation of the LPSs to light the UV lamps. The button is
displayed for login level Advanced operator or higher. The button enables
3 LPS Manual
manual lcontrol of UV lamps.
Component Description
LPS 116 Press one button (116) to start or stop UV lamp 116 manually, controlled
by the LPS.
Status indication:
Start all LPS, and thereby all lamps for the AOT reactor. Requires that the
Manual mode button is pressed.
3 LPS StartAll
Stops all LPS, and thereby all lamps for the AOT reactor.
3 LPS StopAll
The popup gives detailed information about UV intensity for AOT reactors and power for LPSs. The
information is mainly used for advanced trouble shooting by Alfa Lavals personnel.
LPS status
Component Description
AOT Information is displayed for the AOT reactor selected in the AOT number
field.
LPS fail safe Displays if LPSs is active and powered on. UV lamps can only be lit if an
LPS is active. When a critical alarm (e.g. no water in the AOT reactor) is
issued, the fail safe function inactivates the LPSs and cut the power.
Component Description
LPS 116 Actual effect from each LPS to respective UV lamp. Green = LPS/Lamp
on. Gray = LPS/Lamp off.
Power optimization
Component Description
Manual power Manually set effect to LPS. Requires that the system is set in manual
output mode.
In manual mode (login level Advanced operator or higher) it is also possible to operate components
manually. If the component is pressed, a popup window is displayed from which the sub component
can be operated. When manual mode is deactivated the system will return to standby mode: All
manually operated components will return to their status prior to the manual operation.
Component Description
Diff. pressure Indicates differential pressure over the filter (PT20171 minus
PT20172). When the pressure reach the value set in parameter p305,
a backflush is triggered.
Pipes, valves, motor For status indications, see Status indication Component color in
and pump section Flow chart on page 21.
This section contains step-by-step instructions for operating the PureBallast system. Please read
and follow the preparations and conditions carefully, as well as any danger or warning notes.
Control system pages used in the instructions: See section Control system Detailed page
descriptions.
Login levels required for different procedures: See section Login levels on page 11.
Detailed information about components (valves, motors, pumps etc) involved in each step the
process. See section Detailed process description.
4.1 Log in
Follow the steps below
1. Press the expand button on the Log in tab in the top right corner of the screen.
Result: The log in menu is displayed.
2. Press the expand button on the left drop down menu to display available users. Press desired
user.
Result: A keyboard is displayed.
3. Enter password and press Enter. (See section Login levels on page 11.)
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).
Flow must have been selected before a process can be started, either manually or automatically.
See Flow selection on page 19.
There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
Follow the steps below:
2. Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and ballasting starts.
4. When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off. An automatic filter
backflush is performed.
5. Wait for the message Close valves .... Close relevant valves and then press the button in
the popup to confirm the action. Note! These valves are outside outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
6. Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
7. Wait for the Start CIP popup. Choose to start a CIP process or wait.
CIPpop
NOTE
A CIP cleaning process must be finished within the time stated in the popup (30 hours from the first operation
after the previous CIP process). Therefore consider the time for CIP process. A CIP process takes about 25
minutes , if default parameters are used. If no CIP process is performed within the time limit an entry is made in
the control system log file. Operations after the warning does not fullfill the type approval certificate.
Note that it is possible to run operations during the 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean AOT
after ballast / deballast on page 65.
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).
Flow must have been selected before a process can be started, either manually or automatically.
See Flow selection on page 19.
There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
Follow the steps below:
2. Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message Confirm ballast pump started. Start the pump and then press the
button in the popup to confirm the action. Note! This component is outside the PureBallast
system control. (The popup is not displayed if the component feedback is integrated with
the control system.)
Result: Cooling stops and deballasting starts.
4. When desired amount of water has been processed, press the function button Stop.
To get a smooth stop, the flow from the ballast pump can be reduced, but not more than 50 %.
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
6. Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
7. Wait for the Start CIP popup. Choose to start a CIP process or wait.
CIPpop
NOTE
A CIP cleaning process must be finished within the time stated in the popup (30 hours from the first operation
after the previous CIP process). Therefore consider the time for CIP process. A CIP process takes about 25
minutes , if default parameters are used. If no CIP process is performed within the time limit an entry is made in
the control system log file. Operations after the warning does not fullfill the type approval certificate.
Note that it is possible to run operations during the 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean AOT
after ballast / deballast on page 65.
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
Stripping function must be activated in parameter p170.
All ballast system valves outside the PureBallast system must be set in the correct positions
for ballasting. The valve after the ballast pump must be closed (not part of Alfa Lavals scope
of supply).
There must be available power for the system. If power management is integrated, this will
be handled automatically. If power management is not integrated, confirm available power
manually.
Follow the steps below:
2. Wait for the message Open valves .... Open relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Deballast start-up starts, with cooling water cooling the lamps during warm-up.
3. Wait for the message Confirm strip pump started. Start the pump and then press the button
in the popup to confirm the action. Note! This component is outside the PureBallast system
control. (The popup is not displayed if the component feedback is integrated with the control
system.)
Result: Cooling stops and stripping starts.
4. When desired amount of water has been stripped, press the function button Stop.
Result: Ongoing process is stopped and the lamps are switched off.
5. Wait for the message Stop stripping water pump. Stop the pump and then press the button
in the popup to confirm the action. Note! This component is outside the PureBallast system
control. (The popup is not displayed if the component feedback is integrated with the control
system.)
6. Wait for the message Close valves .... Close relevant valves and then press the button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
7. Wait for the Start CIP popup. Choose to start a CIP process or wait.
CIPpop
NOTE
A CIP cleaning process must be finished within the time stated in the popup (30 hours from the first operation
after the previous CIP process). Therefore consider the time for CIP process. A CIP process takes about
25minutes , if default parameters are used. If no CIP process is performed within the time limit an entry is made
in the control system log file. Operations after the warning does not fulfill the type approval certificate.
Note that it is possible to run operations during the 30 hours. Complete status information regarding CIP is
displayed in page 1.3 CIP status. A CIP process is started manually according to instruction CIP clean AOT
after ballast / deballast on page 65.
This is only possible in sub process full ballast or full deballast. This is indicated by the lit
Pause button.
Allowed in sub process full stripping if activated in parameter (p170). After defined time, the
paused process is stopped.
Allowed length of a pause is parameter set (p138). After defined time, the paused process
is stopped.
Follow the steps below:
2. Wait for the message Stop ballast water pump. Stop the pump and then press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: Ongoing process is paused. The UV lamps remains on at reduced power and cooling
water is run through the AOT reactor to cool the lamps. Pause mode is indicated by yellow
light under the Pause button and blinking yellow under the function button Ballast, Deballast
or Strip.
5. Wait for the message Confirm ballast pump started. Start the pump and press the button in the
popup to confirm the action. Note! This component is outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The process is resumed.
This requires that a signal for heeling mode is integrated between PureBallast and the vessels
ISCS.
This is only possible in sub process standby, full ballast and full deballast.
Allowed length of heeling is parameter set (p138). After defined time, the system is stopped.
Follow the steps below:
1. Activate heeling from ISCS, which means that a heeling signal is sent to PureBallast.
2. In PureBallast: Wait for the message Stop ballast water pump. Note! This component is
outside the PureBallast system control. (The popup is not displayed if the component feedback
is integrated with the control system.)
Note: If you you need the ballast pump for heeling, confirm the request without stopping the
ballast water pump.
Result: System goes to heeling mode (ongoing process is paused). The UV lamps remains on
at reduced power and cooling water is run through the AOT to avoid overheating of the lamps.
During heeling, the yellow light under the Pause button is lit and the yellow light under the
function button Ballast or Deballast is blinking.
5. Wait for the message Confirm ballast pump started. Start the pump and press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
Result: The process is resumed.
If system shut down is activated during the CIP process, the CIP liquid is drained to the CIP tank.
Water in the AOT reactors is drained overboard.
The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
We recommend that a CIP process is performed within the same ecological zone or in
international waters (200 nautical miles from the base line). This will avoid untreated water from
the AOT and the filter to enter a different ecological zone.
Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOT reactors
are required to be CIP:ed etc.
If a ballast operation has been performed since the last CIP process, the process is completed
with a filter preservation, where the filter is filled up with fresh water.
Follow the steps below:
2. Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
Result: The CIP process starts. The CIP process takes about 25 minutes for one AOT reactor,
if default parameters are used.
Note: If CIP process is started after a process the CIP process will start after 2 minutes, when
the UV lamps have been cooled.
3. Wait for the message Close valves .... Close relevant valves and then press button in the
popup to confirm the action. Note! These valves are outside the PureBallast system control.
(The popup is not displayed if the component feedback is integrated with the control system.)
An alarm or warning is indicated by a audible signal and that the icon on the alarm list tab is blinking:
3 Alarm
Alarms will shut down ongoing process and disable start of process.
Warnings are information to the operator and will not shut down ongoing or disable start
of process.
An alarm or warning will activate the alarm buzzer (sound and light) on the cabinet. The sound
is silenzed by touching the buzzer, but note that the alarm is not acknowledged by this.
NG
WARNI
!
Never reset an alarm without first finding and attending to the problem.
Requires login level Operator or higher.
For color indication of alarms. See page 32.
Follow the steps below:
3. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
4. After the problem has been dealt with Press the Ack all button to acknowledge all alarms, or
press the alarm row and press Ack selected button to acknowledge only this alarm.
Result: The alarm will change color to indicate change of status. See section Page 2.1 Alarm
list in this chapter. The acknowledge time is updated, and the Normal time will be updated
when the problem is resolved.
PureBallast will shut down if the system loose power (intentionally or unintentionally) or if an alarm
is issued. Alarm has alarm ID beginning with an A.
Events at shutdown:
One of the following methods can be used to abort any ongoing operation and stop the system:
Action Method
3StopButtonBlue
System stop Press the Stop button (2) on the control cabinet door.
Result: Ongoing process is stopped and valves are returned to starting
position as fast as possible. Note: The power is still on.
System stop If an external system stop button has been installed and integrated, it
(External button) will function as the system stop above.
The system may only be reset after the reason for shut down is known. If the reason is not known,
follow the instruction Attend to alarms.
Manual on control cabinet: Turn the main breaker (1) and acknowledge the alarm in the control
system. Release the button on the control cabinet.
Automatic in LDC: Follow the instruction below if a reactor has been shut down by temperature
switch TS201-60 (alarm A137) or if the cabinet or system has been shut down by a blackout or
electrical faults in the cabinet:
1. Make sure that the main breaker (A) on the LDC door is turned on.
2. Press the blue reset button (B) on the LDC door (when the reactor has cooled down or when
the power is back on).
3. Acknowledge all alarm related to the shut down in the control system.
Valves are recommended to be operated via the PureBallast control system. It is also possible to
open/close them manually according to instruction in chapter 7. Service manual, section Operate
valves manually.
3 PopValve
4. Press (not slide) the Hand button icon to enable manual operation of the component.
Result: The open and closed buttons turn blue for operation. A hand icon is also displayed on
the component in the popup and the flow chart to indicate that it is manually operated.
5. Operate the component using the open/run (left) and closed/not running (right) buttons in
the popup.
6. Press Hand button to stop manual mode for the component and the X button to close the popup.
or
Press the X button to close the popup and let the component remain in manually set status.
The popup is closed, and a hand icon is displayed by the component to indicate it is manually
operated.
NGE R
! DA
Manual start of the UV lamps is only allowed (and possible) when there is water in the AOT
reactor (indicated by level switch LS201-29), and the water temperature is below 60 C. All
necessary items cooling water flow, water temperature, and power management must be
supervised and verified by the authorized trained personnel operating the system. Inappropriate
operation of this function could seriously damage the equipment and injure personnel.
1. Go to page 1.1 Overview. Press the Manual function button to activate manual mode.
3. Select which AOT reactor to operate in the AOT number entry field.
4. Open, in stated order, the following valves to fill the AOT reactor with water: 201-19, 404-36
and 403-35.
Result: The AOT reactor is now filled with water through the cooling water line 403.
5. Wait until the AOT reactor is filled with water, indicated by the level switch (LS20129) turning
green.
7. Press the Manual mode button to enable manual operation of the UV lamps.
9. If desired, the UV lamps can be dimmed manually: Press the LPS status button in the AOT
reactor popup. Press the Manual output filed, and enter desired percentage between 50
and 100 %. The LPS will give the entered percentage of full effect to the UV lamps. This is
indicated in the Power output field.
If remote control panels (option) are used, enterd IDs will be displayed on all panels.
Requires login level Advanced operator.
Follow the steps below:
3 ShipIDComp
Information to be Description
exported
Event log The event log includes all important events in the PureBallast system. The
log also include components connected via the log box. Intended to be
used mainly by service technicians.
Event log - Contains a selection of the complete event log, relevant to comply with
Certificate the IMO regulations.
Alarms and A list of all alarms and warnings that has been issued from the control
warnings system. Intended to be used mainly by service technicians.
For specific information about logged events, see section List of logged information on page 87.
Events are only copied, hence they will remain in the control system.
The log and alarm files are stamped with the system name and serial number entered in page
4.5 Installation parameters.
The easiest way of reading the log file is to use the program Visualog, but the file can also
be read in Exel.
Follow the steps below:
3 ExportLog
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
4. Chose one of the following alternatives to decide time interval for the information to be copied:
Recommended: Accept suggested default time interval in the Start and End fields. Default
start date is the oldest file in the system, and default end date is todays date.
Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events or Alarms. (The Update export is only
used when updating softwares.)
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6. Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been saved to the USB. It contains two sub folders:
Alarm and Event. The folder corresponding to your export choices contains a CSV file.
4. Wait for the OK / Close button to turn blue again. If the backup was successful, the last line
shall state "Backup done".
Result: A folder named PureBallast backup has been saved containing the backup files.
3. Press the Restore button in page section Backup and restore, Settings to/from HMI USB.
Result: A popup is displayed and the process is started.
5. Read the second last line in popup: If the restore was successful, it shall state "Restore done".
8. The control panel must be rebooted. At the rear side of the control panel: Pull out the power
cable from the 24V DC port, and insert it again.
3 IPaddress
Enter the IP address according to the list below. Also check that correct setting is done for Port
2 in the Port 2 tab.
3 IPaddress
5. Press OK.
6. Reboot the panel to update communication with the new IP address. Make sure that the new
IP address is displayed on page 4.1 System info.
7. Repeat this instruction for all installed control panels, both main and remote control panels, if
installed.
8. Follow the instruction Set remote control panel communication to activate remote control panel.
1. On the main panel in the control cabinet: Go to page 4.1 System info.
3 RCP communication
5. Press the Panel alias field for the new control panel. Use the keyboard to enter a name, for
example the location it is placed.
Note: Panel alias for all control panels shall be entered (with the same wording) in all panels
to be displayed in a correct way.
If remote control panels are not used, any added control panels shall be deleted from the list.
To delete a connected panel: Select it a panel in the hand side and press the delete (X) button. If a
keyboard is displayed, pres Esc to remove it.
2. Set parameters to match ISCSs RTU server data according to the information in chapter 4.
Parameters, section 5.7 Remote interface.
Test communication
1. Go to page 4.5 Remote interface 1. Make sure that the system is not in test mode (no
checkmark on the button). If not, press the Test mode button to deactivate it. Make sure that
Local operation is activated. If not, press the Local function button.
2. Check that the heartbeat signal is updated in both systems (06 and 77). Also check that values
are read from the PureBallast system, for example temperature (address 116 and 117).
This will confirm that the systems communicate.
Values are entered and displayed in the control system as actual values, but are sent to ISCS using
the binary numeral system. This information is found in group Data to ISCS and Cmd/status to
ISCS on page 4.5 Remote interface 1, and is indicated by a unit (m3, hour, second, kW etc).
The following addresses does not display correct values in page 4.5:
50 Process volume
114/124/134 AOT reactor temperature for AOT reactor 1, 2 and 3
115/125/135 LDC water temperature for AOT reactor 1, 2 and 3
52 System pressure
63 Filter differential pressure
64 Filter inlet pressure V20171 (Hydac filter)
65 Filter outlet pressure V20172 (Hydac filter)
66 V201-8 setpoint
57058. Current time
For detailed information, see the directory of addresses.
2. Enter actual values in the in the input field for the address to send simulated information to
the ISCS. Information in decimal form, for example processed volume, is written as actual
values. Information in binary form, for example command status, is written as a bit pattern.
The key for the bit pattern is found in chapter 6. Installation description and drawings, section
System interfaces.
3. Make sure that values and status information is displayed correspondingly in the ISCS.
In the ISCS, activate input commands corresponding to the addresses displayed in page 4.5. (Note
that address 06 does not need to be tested; it was tested at the beginning of this procedure.)
2. Make sure that the command is received in page 4.5. Use the directory of addresses to see
that the bit pattern is updated correctly.
3. In the control panel, restore all changed values after the communication test. If not, commands
might be executed involuntarily, when the system is set to online again. Most important is that
address 001 displays 00000000.
Alarms and warnings are tested by simulation in control page 4.5 Remote interface 1 and 4.6
Remote interface 2. Use the alarm list to identify addresses and bit patterns for the alarms.
You want to simulate alarm W40 (Process pressure too low). When you find W40 in the table, you
use the column heading to see which address the alarm shall be sent to and the row heading to
see which bit in the bit pattern that shall be high. For W40 the signal shall be sent to address
902, and bit 12 shall be high.
Translate the bit to a bit pattern: Bit 12 is the 13th digit from the right (the first digit from
right is counted as zero, second digit counted as 1 etc). This gives the following bit pattern:
0010000000000000.
AOT reactor alarms/warnings: Each installed AOT reactor has a unique address:
1. Enter the desired bit pattern in the input field for the address.
3. If common alarm and warnings are used, make sure that address 70:7 and 70:8 are updated.
It is only necessary to check this for the first alarm.
6. Press the Test mode button to set the system in online mode (no check mark on the button).
Press the Remote function button if you want to activate remote control.
2. Press the hand button in the Request column for a row with power step for desired number of
AOT reactors. For details, see description of page 1.4 Power request.
3. Press the Request button for the row to simulate power request signal.
Result: Status is updated to Requested in the Request column.
7. Press the Set run button to deactivate the simulate running signal.
1. Pull out the power cable from the 24V DC port on the rear side of the control panel. And
then reconnect the power cable.
For remote control panels: Use the Power button to turn off, and then turn on the power.
2. Wait for a sandglass to appear and disappear. When it appears again, press a finger on the
screen and hold it there for approximately 20 seconds.
Note: Keep holding the finger on the screen even when the panel turns white with a red
message Welcome to ....
3. Wait for the screen to turn completely white with a message Tap anywhere on the screen
within 10 seconds. Release the finger and tap once on the screen.
During ballast and deballast operation, the control valve is PID regulated based on input from the
flow transmitter FIT201-1 to maintain stable flow. Desired flow is defined as selected certified flow
for the operation minus the Undershoot percentage set in parameter p111.
During backflush, the control valve is PID regulated based on input from the pressure transmitter
PT201-16 to maintain stable pressure for efficient backflush. Desired pressure is defined in
parameter p304.
The second goal is to shorten the time from backflush trigger to start of actual backflush. This is
done by shortening the time in p310 (Backflush initial delay) that is done after the movement of
V201-8 has been calibrated.
This instruction shall be read together with the example after the instruction.
1. Perform a backflush.
2. Open page 3.1 Trend (15 min) and analyze the trend curve for V201-8.
Before the backflush, the valve shall move as fast as possible to a steady position where it
creates required pressure. If not, parameter p166 shall be adjusted.
3. Adjust parameters, and perform a new backflush.
4. See if the curve has improved. Repeat until satisfactory result has been achieved.
5. See if the time between backflush initiation and backflush can be shortened . If possible, adjust
parameter p310. See parameter p310 in the example below.
Example
In this example, five backflushes are performed. After the first four backflushes, the PID parameters
where changed for pressure regulation to adjust the movement of the control valve V201-8 before
the backflush.
The illustration is taken from page 3.1 Trend (15 min). Backflush is indicated by the movement
of the backflush valve 309-1 (pink line) and the movement of control valve V201-8 is indicated
by the blue line.
1st backflush Parameter p166 is set to 0.30. But it takes too long time for V201-8 to get into
position to create desired pressure (1). The curve slops downwards in a long bend,
which means that it takes time for V201-8 to find correct position.
2nd backflush Parameter p166 was adjusted to 0.6. This made the valve movement much faster
in the beginning, shown by the steep curve at the beginning. But then a more
slow regulation starts, shown by the soft slope (2). This was a change for the
better, but not enough.
3rd backflush Parameter p166 was increased to 1.2 which resulted in a satisfactory valve
movement (3): A fast movement, followed by a minor adjustment. A small
overcompensation can be noted (curve goes too low), that might be adjusted by
decreasing the value to 1.1.
4th backflush During the first backflushes, parameter p310 was set to 60 seconds. The parameter
defines time between a backflush is triggered and it actually starts. But now, when
V201-8 is calibrated, this time can be shortened. Before the fourth backflush
parameter p310 is set to 15 seconds. The shortened time span is indicated by
the braces in the illustration.
5th backflush No parameter was changed. This backflush is only showed to confirm that the
parameter setting is OK and that the curve (5) for V201-8 is basically the same as
for backflush three and four (3 and 4).
3 CalibExample
Alarm history and important events are logged in the control system. The log also include
components connected via the log box (optional).
The control system store all alarms and relevant events for at least 24 months. The memory has
a vast safety margin but when it is full, data will be deleted starting with the oldest data. Logged
information can be exported to a USB memory stick. See Export control system log files on page 74.
The GPS stamp column indicates if the event is stamped with GPS position (Y=yes, N=no). All
events relevant to the IMO certificate are GPS stamped
This section gives a detailed description of the PureBallast processes. The processes are divided
into three main processes, with sub processes, with indications of automatic and manually initiated
steps.
Ballast
Deballast
CIP
Deactivate system
Change flow
Manual mode.
3 BallastProcess
2. Request from control system to open overboard (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3. Overboard valve opened by operator and confirmed in control system. (Handled automatic, if
external component signal is enabled.)
Component activities:
5. UV lamp warming
Component activities:
Start UV lamps (100 %). If all lamps are not lit within p212, process is stopped.
Start counter: UV lamp runtime.
Start LDC fan.
Set V201-8 (control valve) to 50 %.
7. Time p210 after all lamps are lit: Request from control system to start ballast water pump
(outside PureBallast system). (Handled automatic, if external component signal is enabled.)
8. Ballast water pump started by operator and confirmed in control system. If not confirmed
within 20 seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the
20 seconds), process is stopped.
1. Component activities:
Start automatic control of control valve (V201-8) based on input from the pressure transmitter
Start backflush pump P309 (optional)
After p319 seconds, open V309-1
Start M709-42 .
2. Filter backflush is performed for p308 seconds.
Component activities:
Stop M709-42
Close V309-1
Stop P309 (optional)
Start automatic control of control valve (V201-8) based on input from the flow meter.
3. Differential pressure check. If necessary, the process is repeated.
1. Operator pause the ballast process manually. Pause can also be initiated by an external signal,
for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
2. Set V201-8 (control valve) to parameter (p113) set opening percent.
3. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. BW pump stopped by operator and confirmed in control system. Component activities:
- Open V404-36 (AOT reactor outlet, cooling water) on running AOT reactors
- Stop counter: Accumulated water
- Open V403-35 (cooling water inlet)
Start P403-1 (AOT cooling water pump) (if used)
- Close V201-3 (filter inlet)
- Close V201-20 (reactor outlet) on running AOT reactors
- UV lamps dimmed to 50 %
Close V201-8 (control valve).
5. System in pause mode
6.
Resume ballasting
Operator resumes the ballast process manually.
Component activities:
7. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
8. BW pump started by operator and confirmed in control system. (Handled automatic, if external
component signal is enabled.)
- Start automatic control of control valve (V201-8) based on input from the pressure
transmitter
- Open V309-1
- Start M709-42 .
3. Backflush is performed. Approximate duration: 20 seconds.
- Stop M709-42
- Close V309-1.
4. Request from control system to stop ballast water pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
3 DeBallastProcess
Start UV lamps (100 %). If all lamps are not lit within p212, process is stopped.
Start counter: UV lamp runtime.
Start LDC fan.
Set V201-8 (control valve) to 50 %.
8. Time p210 after all lamps are lit: Request from control system to start ballast water pump
(outside PureBallast system). (Handled automatic, if external component signal is enabled.)
9. BW pump started by operator and confirmed in control system. If not confirmed within 20
seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the 20
seconds), process is stopped.
Component activities:
1. Operator pause the deballast process manually. Pause can also be initiated by an external
signal, for example when heeling is initiated from the ISCS. In this case, the process is resumed
automatically when the heeling signal is deactivated.
Component activities:
4. Resume deballasting
Operator resume the deballast process manually.
Component activities:
5. Request from control system to start ballast water pump (outside PureBallast system).
(Handled automatic, if external component signal is enabled.)
6. BW pump started by operator and confirmed in control system.
Component activities:
3 StrippingProcess
5. UV lamp warming
Component activities when power has been granted:
Start UV lamps (100 %). If all lamps are not lit within p212, process is stopped.
Start counter: UV lamp runtime.
Start LDC fan.
Open V201-20 (reactor outlet)
Set V201-8 (control valve) to 50 %.
8. Time p210 after all lamps are lit: Request from control system to start stripping pump (outside
PureBallast system). (Handled automatic, if external component signal is enabled.)
9. Stripping pump started by operator and confirmed in control system. If not confirmed within
20 seconds, lamp power is reduced to 50 %. If not confirmed within p141 (including the
20 seconds), process is stopped.
Component activities:
1. Component activities when minimum process flow established (p172), indicated by FIT201-1:
4. Resume stripping
Operator resume the stripping process manually.
Component activities:
5. Request from control system to start stripping pump (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
6. Stripping pump started by operator and confirmed in control system.
Component activities:
3 CIPprocess
- Stop P321-5
- Close V571-1 (CIP, deaeration valve)
- Close V460-2 (CIP, drain valve)
- Close V3212 (AOT reactor, upper CIP return valve)
- Close V3204 (AOT reactor, lower CIP return valve).
6.5.8 Repeat
When CIP process is done for the first AOT reactor, the remaining AOT reactors with status CIP
required are processed in the same way.
1.
Component activities when all required AOT reactors are processed:
- Open V310-1
- Open V309-1
- Start M709-42.
2. Component activities after the filter is filled:
- Stop M709-42
- Close V309-1
- Close V310-1.
3. Request from control system to close overboard valve (outside PureBallast system). (Handled
automatic, if external component signal is enabled.)
4. Overboard valve closed by operator and confirmed in control system.
Requires login level 2. The Manual mode button is only displayed for login level 2.
Flow in pipes is not indicated in flow chart.
Can only be activate from standby mode.
No automatic processes can be run.
If another operator take over command by logging in on another control panel, manual mode is
deactivated, and the system returns to standby.
1.1 Introduction
This is a quick guide to the most common routines performed in the PureBallast control system.
More detailed instructions are found in the PureBallast manual.
The Alarm list (page 2.1) must be controlled to verify that there are no alarms needing attention.
Flow must have been selected before a process can be started. If the Auto button is selected
(checkmark) maximum flow is automatically selected, and flow can only be changed during
process according to instruction Change ballast / deballast / stripping flow. If parameter the
Auto button is deselected (no checkmark) last selected flow is used. Otherwise, flow is selected
on page 1.1 Overview or 1.2 AOT and flow selection.
1.2 Ballast, deballast and stripping
Follow the steps below
3. Wait for the message Open valves .... Open relevant valves and then press the button in
the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
4. Wait for the message Confirm ballast pump started. Start the pump and then press the button
in the popup to confirm the action. (The popup is not displayed if the component feedback is
integrated with the control system.)
5. When desired amount of water has been processed, press the function button Stop to end
the process.
6. Wait for the message Close valves ... and Stop ballast water pump. Handle accordingly.
(The popups are not displayed if the component feedback is integrated with the control system.)
Book No. 5
1.4 CIP clean AOT 1 Quick guide to PureBallast operations
7. Wait for the Start CIP popup. Choose to start a CIP or wait maximum the time stated in
the popup.
CIPpop
An alarm is indicated by a audible signal and by a blinking warning icon in the control panel.
Never reset an alarm without first finding and attending to the problem.
Follow the steps below:
3. If the process have stopped: Take action to eliminate what has caused the alarm.
4. If the alarm is caused by a faulty AOT module, the ballast/deballast process has to be restarted
with another AOT according to the Perform ballast instruction.
5. If the process continues: Consider if the process shall be terminated. Take action to eliminate
what has caused the alarm.
Press the Ack selected or Ack all button after the problem has been dealt with.
The system must be in standby mode. This means that this operation cannot be executed
during ballast or deballast.
Complete status information regarding CIP is displayed in page 1.4 CIP status. The page
displays remaining time for ongoing CIP cycles, remaining time before individual AOTs are
required to be CIP:ed etc.
6 Book No.
1 Quick guide to PureBallast operations 1.5 Export control system log files
3. Wait for the message Open valves .... Open relevant valves and then press button in the
popup to confirm the action.
Result: The automatic CIP cycle starts. The CIP cycle takes about 25 minutes per AOT.
4. Wait for the message Confirm overboard valve closed. Close the valve and then press button
in the popup to confirm the action.
3. Wait for message: Insert USB in PLC. Insert a USB memory in USB PLC port on the cabinet
door.
4. Chose one of the following alternatives to decide time interval for the information to be copied:
Accept suggested default time interval in the Start and End fields. Default start date is the
oldest file in the system, and default end date is todays date.
Select the Specify time interval box, and enter desired interval in the Start and End fields.
5. Press one of the following function buttons: Events, Cert events or Alarms.
Result: The information is copied to the USB memory indicated by a green checkmark on
the button during copying.
6. Wait for the message "Export OK" to appear. If desired, export next category of events using
the function buttons.
Result: A folder named PureBallast has been downloaded. It contains three sub folders:
Alarm, Cert and Event. The folder corresponding to your export choice contains a CSV file.
Book No. 7
Chapter: 4. Parameters
System manual PureBallast 3.1 Flow 1000
3
1 Introduction
This chapter contains information about parameters in the control system and flow transmitter.
It covers:
This section describes all parameters set in the PureBallast control system.
NOTE
Parameters in bold can only be changed by login level AlfaLaval. Parameters in normal text can
be changed by login level Advanced operator.
The parameter settings can be exported to a USB memory for safety backup, and be restored
from a backup. See chapter 3. Operating instructions and control system description for
instructions.
Parameters are valid for PLC software version V3.1.1.
The installation specific parameters are set to reflect the specific installation and shall normally only
be checked and adjusted at first start up, during preparations for commissioning.
The installation specific parameters are found in the pages listed below:
- p200, p201, p208 and 216: Time-out parameters for draining and filling AOT reactor.
These parameter are evaluated during the commissioning preparation test and adjusted if
necessary.
NOTE
2. To see allowed range (maximum and minimum values) and change setting, press the blue
button (with the parameter ID). A button pair is displayed.
4 ParaIntervalSet
Press the sign to display range. Entered parameter value must be within defined setting
range.
4 MinMax
4. Enter the setting and confirm by touching the Enter button. To close the keyboard without
saving data, touch the Esc button.
If the parameter is set with a drop down menu, select desired choice by touching the value.
Result: The setting is saved directly, it is now safe to leave the page.
4 5.1
p100 High pressure, 7.00 110 bar Setpoint for shut down due to high
shutdown trigger pressure at PT201-16. Default value
(PT201-16) shall be used.
p101 High pressure, 6.00 010 bar Setpoint for warning due to high pressure
warning trigger at PT201-16. Default value shall be used.
(PT201-16)
(6 bar = 0.6 MPa)
p103 Low pressure, 0,0 -12 bar Setpoint for warning due to low pressure
warning trigger at PT201-16.
(PT20116)
(1 bar = 0.1 MPa)
p113 Min % open for 20 10100 % During ballast and deballast, valve
V201-8 V2018 handles the automatic pressure
and flow control.
p116 Low flow shut 10 1090 % Set point for shut down due to low flow,
down limit defined as percent of certified flow.
(FIT201-1)
Default value shall be used.
p117 Max delay of CIP 6 024 hrs Define max delay, in hours, before a CIP
cycle, hours process must be performed after ballast
or deballast. Default value shall be used.
p118 Max delay of CIP 1 030 day Define max delay, in days, before a CIP
cycle, days process must be performed after ballast
or deballast. Default value shall be used.
p119 Valve travelling 5 110 sec Maximum time for V2018 to go from
time for 201-8 opened to closed, and vice versa, before
a warning is issued.
p120 V2018 PID 0.30 0.00 N/A Defines proportional gain (Pf) value used
proportional gain 10.00 for PID regulation of V2018 during
ballast and deballast.
p121 V2018 PID 7.00 0100 sec Defines integral time (If) value used for
integral time PID regulation of V2018 during ballast
and deballast.
p122 V2018 PID 0.0 0.0100.0N/A Defines derivate gain (Df) value used for
derivative gain PID regulation of V2018 during ballast
and deballast.
Normal value: 0.
p138 Timeout: Time 5 130 min Defines maximum time a ballast and
in Pause before deballast process can be manually
going to Stop paused. After defined time, the process
is stopped.
p140 Timeout: 5 130 min Time the control system will wait for
Request "Confirm confirmation signal from ISCS, hard
overboard valve wire or manually in popup before
open" displaying message that operation was
not performed.
p141 Timeout: Request 1 13 min Time the control system will wait for
"Confirm pump confirmation signal from ISCS, hard wire
started" or manually in popup. After that the
process is stopped.
p143 Timeout: Power 60 1300 sec Time the control system will wait for
granted signal not confirmation signal from ISCS that the
received operation was performed.
4 5.2
Not used
Hardwire ranged
Hardwire fixed
Remote interface (requires that p132
is activated)
p128 Max time 60 15240 Sec Define max delay before the system
communication shuts down after communication is
loss PLC/remote lost between the PLC and the remote
interface interface (optional). The value must be
greater than the heartbeat signal interval
defined in the ISCS.
p129 Booster pump Not N/A Drop Defines if an LDC cooling water pump
(P401-1) for LDC used list (not part of Alfa Lavals scope of supply)
cooling water is used to create sufficient cooling water
flow to the LDC.
p130 Booster pump Not N/A Drop Defines if an AOT cooling water pump
(P403-1) for used list (not part of Alfa Lavals scope of suppy)
reactor cooling is used to create sufficient cooling water
water flow to the AOT reactor.
p132 Remote interface Not N/A Drop Defines if remote interface (optional) is
via modubus used list used and connected via modbus.
p135 External system Not N/A Drop Defines if an external system stop button
stop used list (or signal) is installed.
p137 Hide Pause Acti- N/A Drop Defines if the Pause button is visible or
button vated list hidden in the control system. If activated,
the button is hidden.
p160 GPS Not N/A Drop Only valid if RMC protocol is used for
used list GPS integration.
p161 Time interval for 1.0 0.1 Min. Time interval to update the amount (m3)
log event 331 60.0 of ballast water treated in log file.
p162 Time interval for 1.0 0.1 Min. Time interval to update the amount (m3)
log event 341 60.0 of deballast water treated in log file.
p163 Additional bypass Not N/A Drop Defines if an additional bypass valve is
signal 1 used list used. The signal gives information if the
valve is opened during process, so that
PureBallast is bypassed.
p164 Additional bypass Not N/A Drop Defines if a second additional bypass
signal 2 used list valve is used. The signal gives
information if the valve is opened during
process, so that PureBallast is bypassed.
p165 Additional bypass Not N/A Drop Defines if a third additional bypass valve
signal 3 used list is used. The signal gives information if
the valve is opened during process, so
that PureBallast is bypassed.
p166 Pressure PID 0.60 0.00 N/A Defines proportional gain (Pf) value used
proportional gain 10.00 for PID regulation of V2018 during
backflush.
p167 Pressure PID 7.0 0.0 sec Defines integral time (If) value used
integral time 100.0 for PID regulation of V2018 during
backflush.
p168 Pressure PID 0.0 0.0 N/A Defines derivate gain (Df) value used
derivate gain 100.0 for PID regulation of V2018 during
backflush.
Normal value: 0.
p172 Minimum flow 10 790 % Set point for shut down due to low flow,
when stripping defined as percent of certified flow.
(FIT2011)
Default value shall be used.
p172 Minimum flow 10 790 % Set point for shut down due to low flow,
when stripping defined as percent of certified flow.
(FIT2011)
Default value shall be used.
4 5.3
p200 Timeout: AOT 2 0.510.0 min Time the control system will wait for
draining confirmation that an AOT reactor is
drained before an alarm is issued.
Recommended setting: Approximately 1
minute more than actual drain time.
p201 Timeout: Reactor 2 110 min Time the control system will wait for
cooling water confirmation that cooling water has filled
(LS201-29) the AOT reactor before an alarm is
issued.
p202 High temp, 60 10100 C Setpoint for high water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) AOT reactor. Default value shall be used.
p204 Low temp, -2 -540 C Setpoint for low water temperature alarm,
alarm trigger indicated by temperature transmitter in
(TT201-33) the AOT reactor. Default value shall be
used.
p206 Alarm delay for 5 010 sec Delay before alarm is issued after setpoint
sensor TT201-33 temperature (p202 and p204) is reached.
p208 Timeout: CIP fluid 5 115 min Setpoint for max time to fill an AOT
fill-up time AOT reactor with CIP liquid during CIP process
before an alarm is issued.
p210 UV lamp warm-up 90 090 sec Warm up time for UV lamps before full
time ballast or deballast starts. Default value
shall be used.
p211 UV lamp cooling 300 180600 sec Cooling time for UV lamps after ballast or
time deballast. Default value shall be used.
p212 Timeout: UV 60 1060 sec Time the control system will wait for
lamp ignition confirmation signal that UV lamps are
ignited. If no lamps are ignited or if
less lamps than set in parameter p213
are ignited, the AOT reactor will be
automatically stopped. Default value
shall be used.
p215 Alarm delay for 5 010 sec Delay before shutdown when there is no
LS201-29 water in an AOT reactor, indicated by
level switch in AOT reactor (LS201-29).
Default value shall be used.
p216 Timeout: Fluid 5 210 min Setpoint for max time to fill an AOT
fill-up time AOT reactor with fresh water during CIP
process before an alarm is issued.
p221 Low UV intensity 550.0 0 W/m2 Setpoint for warning due to low UV
warning trigger 1000 intensity indicated by UV sensor
QT20150 in the AOT reactor. This
warning will be logged in the Event log.
p231 Cabinet 40.0 20.0 C Setpoint for LDC cooling fan regulation.
temperature 60.0 When the temperature is below setpoint,
low threshold the fan is running at 30 % of full effect.
(TT401-2)
At setpoint the fan effect is increased
proportional to temperature from 30 %
up to 100 % at temperature set in p232.
Default value shall be used.
p232 Cabinet 45.0 20.0 C Setpoint for running the LDC cooling fan
temperature 60.0 at 100 %.
high threshold
(TT401-2)
p234 UV control 0.10 0.00 N/A Defines proportional gain (Pf) value used
proportional gain 100.00 for PID regulation of UV lamp effect.
Default value shall be used.
p235 UV control 15 0100 sec Defines integral time (If) value used for
integral time PID regulation of UV lamp effect.
4 5.4
p300 High filter 3 110 bar Setpoint for shut down due to high
diff. pressure differential pressure over the filter. Default
shutdown trigger value shall be used.
p301 High filter 1.5 0.0- bar Setpoint for high pressure warning,
differential 2.0 indicated by pressure transmitter in the
pressure, filter.
warning trigger
(1.5 bar = 0.15 MPa)
p304 Pressure setpoint 2.50 1.00 bar Defines desired pressure for efficient
during backflush 5.00 backflushing.
p305 Backflush trigger, 0.50 0.00 bar Setpoint for automatic start of filter
differential 2.00 backflush due to dirt in the filter, indicated
pressure by high differential pressure over filter.
(PT201-27)
Note: This parameter can be adjusted, but
only by Alfa Laval during commissioning.
If adjusted, parameter p301 shall be set
to 30 percent higher.
p310 Backflush initial 10 060 sec Defines how long time that should pass
delay from a backflush is triggered until is
actually started.
p311 Backflush delay 2.0 0.0 sec Defines for how many seconds the
(p305 during x 10.0 differential pressure defined in p305 must
sec). last, before automatic backflush starts.
p313 Differential 5 030 sec Time constant for low pass filter used for
pressure the differential pressure over the filter.
measurement The low pass filter is used to smoothen
filter the effect of sudden changes in differential
pressure (primarily pressure peaks after
completed backflush).
p315 Filter type 6000 100 m3/h Parameter p314 should be set before this
6000 parameter. Available alternatives depend
on selection in p314.
p318 Backflush pump Not N/A Drop Defines if an LDC cooling water pump
(P309) used list (not part of Alfa Lavals scope of suppy)
is used to create sufficient backflush flow
in pipe 309.
4 5.5
p400 CIP cycle time 15 160 min Duration of circulation of CIP liquid
during a CIP process.
4 5.6
System name N/A N/A N/A Possibility to enter a system name for
the system, for example Vessel name
when logged in as login level Advanced
operator or higher. If two systems is
installed information about starbord and
port side.
fisk
p112 Maximum flow 1200 0 m3/h The parameter shall be set according to
(FIT201-1) 3000 pipe dimension for the flow meter pipe.
p131 Automatic AOT Not N/A Drop Defines if AOT reactors shall be
selection used list automatically selected for process.
p213 Allowed no. of 0 01 No. If more lamps than set in this parameter
failed UV lamps are broken, it is not allowed to start a
per AOT reactor new operation.
p217 AOT reactor size 300 N/A Drop Defines size of the AOT reactor, defined
list as max capacity (m3/h).
Alternatives: 300, 600 and 1000.
p150 EX proof system Not N/A Drop Defines if the EX proof version of
used list PureBallast is installed. This affects
both installation and control system.
p500 Log box Not N/A Drop Defines if the log box (optional ) is
used list installed to monitor and log external
valves and pumps, that are not part of
Alfa Lavals scope of supply.
4 5.7
Parameters for the ISCS modbus RTU server data shall be set according to the information below.
p700 Interface type RS485 N/A Drop Defines communication (cable) type
list used for communication between the
ISCS and PureBallast.
p701 Baud rate 9600 N/A Drop Defines baud rate in bits per second.
list
The parameter can be changed, but
it is not recommended. Note, that the
information must be the same in ISCS
and PureBallast control system.
p703 Data bits 8 N/A Drop Defines data bits per character. Default
list value shall be used.
Alternatives: 7 or 8.
p704 Stop bits 1 N/A Drop Defines number of stop bits. Default
list value shall be used.
Alternatives: 1 or 2.
This section describes the parameters set in the parameter pages in the flow transmitter, installed
on the flow meter.
General (non-installation specific) parameters are preset to function for all systems. They must only
be adjusted, by Alfa Laval, if required by performance reasons or similar. They are checked during
preparations for commissioning and shall normally not be adjusted after start up.
4FTPanel
Buttons used:
2. Press Padlock.
Result: A line appears under the first zero.
7. Check that the parameter is set to the same frequency as used on the vessel. (Ask the crew
for information):
a: To change: Press Padlock.
b: Press Change to change (toggle) the setting.
c. Press Padlock to set the value.
Flow direction
(Direction of flow measured in the flow meter.)
Set Qmax
(Measuring range for the flow meter: the analog outputs and the frequency output.)
9. Check that the parameter is set according to the flow direction in the pipe.
a: To change: Press Padlock.
b: Press Change to change (toggle) the setting.
c. Press Padlock to set the value.
11. Check that the parameter is set according to pipe dimension for the flow meter pipe:
100 300
150 300
200 700
250 1200
300 1200
350 1700
400 2200
450 3300
500 3300
600 3300.
a: To change: Press Padlock.
b. Press Select to select digit to change (A line is placed under the changeable digit).
c. Press Change to change (toggle) the digit.
d: Press Padlock to set the value.
17. Press Padlock to display the setting. Check that the parameter is set to On.
a: To change: Press Padlock.
b: Press Change to change (toggle) setting.
c: Press Padlock to set the value.
18. Press Forward until Current output (mA setting) is displayed. Check that the parameter is
set to 4-20 mA.
a: To change: Press Padlock.
b: Press Change to change (toggle) setting.
c: Press Padlock to set the value.
This section describes the parameters (DIP switch settings) set in the LPS, installed in the lamp
drive cabinet (LDC). Each LPS is set to identify the individual LPS in the installation.
Switch 1-3 shall always be in position off. Switch 4-8 is set to identify the individual LPS according
to the table below. Only position ON is indicated. For empty cells in the table, the switch shall be
in position OFF.
LPS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
116
SW 1
SW 2
SW 3
SW 4 ON
SW 5 ON ON ON ON ON ON ON ON
SW 6 ON ON ON ON ON ON ON ON
SW 7 ON ON ON ON ON ON ON ON
SW 8 ON ON ON ON ON ON ON ON
Example
4 LPSdip
NGE R
! DA
Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V) inside
and on the lamp power connector, even when UV lamps are not lit.
The LDC contains a fan, which can cause injury if in operatoin.
Follow the steps below
1. Unscrew the plastic lid (1) over the DIP switches on the fron of the LPS.
7 LPSdip
2. Use a small screw driver to change position of the swithces according to the table under
instruction DIP switch settings.
3
1 Introduction
This chapter covers information about alarms and warnings, together with information about how
to solve the problems causing the alarms to trip. The chapter also contains a list of solutions for
problems that may occur, but that is not indicated by any system.
control system
lamp power supply (LPS)
flow meter (with fault finding instruction)
I/O system and X20 modules.
See chapter 3. Operating instructions and control system description to find information about
the alarm pages and how to attend to alarms.
This section lists all alarms and warnings related to the PureBallast system.
Alarms
A red ligth in the exclamation mark on panel frame is lit. New alarm = blinking.
Acknowledged alarm = Steady.
Warning
All alarms are displayed in the control panels page 2.1 Alarm list and are sorted in order of
occurrence; most recent alarm at the top of the list.
Column in Description
table
- A = Alarms stop the ongoing process, which can be restarted after the
problem has been attended to.
- W = Warnings are notification of a status change or a problem. Warnings
allow the process to continue.
Alarm text / The text displayed in the control system. Note that AOT reactor number is
Problem indicated by x in the table, instead of the actual AOT reactor number. In the
control system alarm text, the actual AOT reactor number is stated for the AOT
reactor concerned.
For problems not indicated by an alarm, the text gives a general explanation
of a problem that can occur.
Trigger / Trigger: Source of the alarm or warning, identified by the input sensors item
Parameter number or equivalent.
Parameter: The parameter controlling the alarm, when applicable.
Delay: Time before the alarm is activated after the condition of the alarm is met.
Comments: Additional information or explanations.
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A01 Process Trigger: PT201-16 Delay: 30 sec. Ballast water pump Check pressure and flow from
pressure too Parameter: p100 gives too high ballast pump(s). If the pressure
high (PT201-16). Comment: Pressure pressure. exceeds set value: Adjust incoming
Automatic stop. transmitter PT201-16 pressure to PureBallast.
indicates pressure
higher than set in Valves in the system Control that correct valves are
parameter p100. after pressure functioning and opened for current
List of alarms and warnings
9
Control system
10
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A03 Process Trigger: PT201-16 Delay: 30 sec. Signal missing 1. Check fuse F45 in Control
pressure or pressure cabinet to see what circuit
signal missing Comment: Error transmitter PT201-16 caused the fuse trip.
(PT201-16). in system pressure malfunction.
2. Use the circuit diagram to
Control system
W04 Process Trigger: PT201-16 Delay: 30 sec. See possible cause See A01.
pressure too Parameter: p101 for A01.
high (PT201-16). Comment: Pressure
higher than parameter
set limit.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A10 Process flow Trigger: FIT201-1. Delay: 5 sec. Signal missing or flow 1. Check fuse F45 in Control
signal missing Parameter: N/A transmitter FIT201-1 cabinet to see what circuit
(FIT201-1). Comment: Error in malfunction. caused the fuse trip.
system flow sensor.
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.
List of alarms and warnings
transmitter display,
message error)
11
Control system
12
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W12 Process Trigger: FIT2011 Delay: 30 sec. Flow rate higher than Reduce the incoming ballast water
flow higher Parameter: N/A selected certified flow to the PureBallast system.
than certified flow, for the number
(FIT201-1). of AOT reactors in
Control system
A13 Process flow too Trigger: FIT2011 Delay: 20 sec. Flow too low. Increase flow.
low (FIT201-1). Parameter: p116
Comment: If flow Make sure the ballast water
Automatic stop.
is less than set in from the ballast pump is
parameter p116, the directed to PureBallast. When
system is shut down. OK the process will continue
automatically.
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
process description.
A14 Process Trigger: FIT201-1 Comment: Triggered Control valve V2018 See alarm A17.
flow too low Parameter: p116 if flow defined in p116 malfunctions.
during start-up is not established
(FIT201-1). within 60 seconds after Flow too low. See alarm A13.
Automatic stop. ballast water pump is
started.
2.1
13
Control system
14
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A17 Valve error Trigger: Limit switch Delay: 15 sec. Fuse tripped. 1. Check fuses F43 in control
(V201-3). GS201-3. cabinet to see what circuit
Parameter: N/A. Comment: Error on caused the fuse trip.
valve V2013.
2. Check relay K1 and K2 on
Control system
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
actuator.
A19 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause Check relay K7 and K8 on module
(201-32) GS201-32. for A17. X10.
2.1
15
Control system
16
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A23 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause Check relay K5 and K6 on module
(V201-9). GS201-9. for A17. X10.
Parameter: N/A. Comment: Error on
valve V2019.
Control system
A25 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V404-35) GS201-35. for A17.
Parameter: N/A. Comment: Error on
valve V20135.
A29 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V201-8). GS201-8. for A17.
Parameter: N/A. Comment: Error on
control valve V2018. Sensor error. 1. Check open indication in the
Shows open all pneumatic positioner.
the time.
2. Check fuses F43 in control
Signal error 420 cabinet to see what circuit
mA. caused the fuse trip.
3. Check relay K3 on module X10.
4. Use the Control cabinet /
Circuit diagram to check the
fuse setting, adjust according
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A33 Bypass valve is Trigger: Limit switch Delay: 15 sec. The valve has been If not opened intentionally, close
List of alarms and warnings
A35 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V212-31). GS212-31. for A17.
Parameter: N/A Comment: Shutdown
of all steps except CIP.
The alarm does not
prevent completion or
start of CIP process.
2.1
17
Control system
18
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W40 Process Trigger: Pressure Delay: 2 sec. Ballast water pump Check that pressure and flow
pressure too low transmitter: gives too low from ballast pump(s) is according
(PT201-16). PT201-16. pressure. to requirements in chapter 6.
Parameter: p103. Installation description and
Control system
A48 System stop Trigger: Stop button Delay: None. Process has been
activated (Stop on control cabinet stopped. NOTE
button). Parameter: N/A
Find out the reason why the process
has been stopped before releasing the
button and starting another process.
2
A49 System stop Trigger: Stop button Delay: None See A48.
activated during on control cabinet
CIP (Stop Parameter: N/A
button).
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A50 System stop Trigger: External Delay: None. Process has been
activated stop button on control stopped by external NOTE
(External stop cabinet (or signal). stop button or signal
button). Parameter: p135 from the ISCS Find out the reason why the process
(integrated ship has been stopped before releasing the
control system). button and starting another process.
W58 Fuse tripped in Trigger: Control Delay: None. Possible reasons: 1. Check fuse F43F45 in control
control cabinet. cabinet. cabinet to see what circuit
Parameter: N/A caused the fuse trip.
short circuit
2. Use the circuit diagram to
overheated fuse
locate the component or find
the reason that caused the fuse
trip and attend to it.
3. Use the circuit diagram for
control cabinet to check the
fuse setting, adjust according
to figures in circuit diagram if
necessary and reset fuse.
2.1
19
Control system
20
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A66 Additional Trigger: External Delay: 5 sec. The valve has been If not opened intentionally, close
bypass valve system. opened manually or the valve.
1 is open. Parameter: p163 Comment: If the valve via the ISCS.
(not controlled by
Control system
PureBallast) is opened,
any ongoing process is
stopped.
This alarm is not
issued when the valve
is opened during mode
standby, heeling or
pause.
A69 Remote system Trigger: External Delay: 5 sec. PureBallast is If valve is not opened intentionally,
reports system system. bypassed via the close the valve.
is bypassed. Parameter: ISCS.
2
A71 Ballast water Trigger: Control Delay: Set in Faulty connection of Check that all electrical connections
pump is system timer. parameter p141. signal cable. are OK. Check that the signal
not running. Parameter: p141. wiring is according to information in
Automatic stop. Comment: Feed back chapter 6. Installation description
signal BW pump is and drawings, section External
running is deactivated component signal integration.
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
between PureBallast and control system descriptionTest
and ISCS is wrong. remote interface communication
A72 Stripping pump Trigger: Control Delay: Set in See possible cause
List of alarms and warnings
A75 Overboard valve Trigger: Control Delay: Set in See possible cause
is not open. system timer. parameter p140. for A71.
Automatic stop. Parameter: p140
Comment: Feedback
overboard valve is
OPEN.
A77 Error on all Trigger: AOT Delay: None An active alarm exist Check page 2. Alarm list in control
operating reactors on all installed AOT panel for related alarms.
AOT:s. Parameter: N/A Comment: All reactors. It can be
Automatic stop. AOT reactors are the same error for
deactivated. all AOT reactors, or
different errors.
2.1
21
Control system
22
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
A79 Power is Trigger: Control Delay: Set in Power management Investigate if the reasons for not
not granted. system timer. parameter p143. master system not granting power is outside the
Automatic stop. Parameter: p127. granting power. PureBallast system.
Comment: No
Control system
W80 Power is not Trigger: Power Delay: None. See possible cause
fully granted. management system. for A79.
Flow capacity Parameter: p127. Comment: Not all
reduced. requested power steps Not enough power Continue process with lower flow
are granted. Triggered has been granted. capacity or try later.
2
if number or requested
power steps does
not match number of
granted power steps.
W82 Heeling mode Trigger: Heeling Delay: 2 sec. Heeling mode has
requested (internal transfer) been activated by
by operator. requested in control Comment: The system external system.
Automatic system. is set in pause mode.
pause. Parameter: N/A If operation has not
been requested: See
A71.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W83 Heeling mode Trigger: Heeling Delay: None. See possible cause
cancelled (internal transfer) not for W82.
by operator. requested in control Comment: Process
Process system. is resumed after being
resumed. Parameter: N/A phased during heeling.
A91 PLC lost Trigger: Control Delay: 60 sec. Panel is switched off 1. Switch on the panel.
communication system PLC. or faulty.
Comment: After 2. Restart the panel. See problem
with all control Parameter: N/A
List of alarms and warnings
23
Control system
24
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W92 Main control Trigger: Control Delay: 30 sec. Master panel is See A91.
panel lost system PLC. switched off or faulty.
communication Parameter: N/A Comment: After
with the PLC. communication is lost, Faulty cable See A91.
ongoing process is connection.
stopped in a controlled
way and the system
is shut down. This
message is visible in
the main control panel.
A93 Heart beat signal Trigger: Control Delay: Set in To operate PureBallast when communication is down,
from remote system PLC. parameter p128. follow the steps below:
interface is not Parameter: p132
updating. Comment: After 1. Set the system to Local mode: Press the Local button
communication is on the control panel.
lost between ISCS
2. Run the system from the control panel. Note that you
and PLC, ongoing
will need to confirm two messages from the control
process is stopped in a
panel during operation: "Confirm ballast pump started"
controlled way and the
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
remote interface integration, you
can disregard this alarm. If not
deactivate the test mode again in
page 4.5 Remote interface 1.
25
Control system
26
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W95 PLC battery low. Trigger: Control Delay: 10 sec. The voltage in the Replace PLC battery in the control
system PLC. battery in the control cabinet.
Parameter: N/A system PLC is too
low.
W96 GPS signal not Trigger: Control Delay: 5 sec. Faulty electrical Check that the signal wiring
valid. system PLC. connection. is according to in chapter 6.
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W97 PLC error in Trigger: N/A Delay: 2 sec. Error in module. Check the LED error indication for
control cabinet. Parameter: N/A the electronic modules in the LDC.
See section I/O system and X20
modules on page 57.
W100 AOT [x]: AOT Trigger: AOT Delay: Set in High temperature Check that the inlet valves
temp too high temperature parameter p206. due to obstacles or (V201-19.x, V403-35) and
(TT201-33). transmitter TT201-33. error in one or more outlet valves (V201-20.x,
AOT shutdown. Parameter: p202 Comment: If components involved. 404-36.x) open properly by
temperature rises operating them manually.
above parameter set See the instruction Operate
value, the AOT reactor components manually
will shutdown. in chapter 3. Operating
instructions and control system
If the alarm trips description.
during operation
with a flow through Check that cooling water supply
the AOT reactor, the (403) is within specification
valves V201-19.x and in chapter 6. Installation
V201-20.x will close. description and drawings,
2.1
27
Control system
28
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W101 AOT [x]: AOT Trigger: AOT Delay: Set in See possible cause
temp too low temperature parameter p206. for W100.
(TT201-33). transmitter TT201-33.
AOT shutdown. Parameter: p204. Sea water too cold; See to that incoming water is
temperature below 0 warmer than 0 C.
C.
W102 AOT [x]: Trigger: AOT Delay: Set in parameter Signal missing 1. Check fuse F42 in LDC to see
AOT temp temperature p206. or transmitter what circuit caused the fuse
signal missing transmitter TT201-33 TT201-33.x trip.
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W107 AOT [x]: LDC Trigger: LDC Delay: 15 sec. No cooling water to Check that cooling water supply
cooling water temperature the heat exchanger. (401) is within specification in
temp too high transmitter TT401. chapter 6. Installation description
(TT4011). Parameter: p214 and drawings, section Connection
list in the General drawings section.
29
Control system
30
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W109 AOT [x]: Trigger: LDC Delay: 5 sec. Signal missing or 1. Check fuse F42 in LDC to see
LDC cabinet temperature transmitter TT401 what circuit caused the fuse
temp missing transmitter TT4011. malfunction. trip.
(TT4011). Parameter: N/A
2. Use the circuit diagram for the
LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.
3. Use the circuit diagrams for
the LDC and AOT reactor to
locate the component or find
the reason that caused the fuse
trip and attend to it.
4. Check cables to the
component. See Lamp drive
cabinet (LDC) / Circuit diagram
in chapter 6. Installation
description and drawings.
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W111 LDC air Trigger: Delay: 15 sec. LDC faulty. Check page 2. Alarm list in control
List of alarms and warnings
W113 LDC cabinet Trigger: Delay: 5 sec. Signal missing or flow 1. Check fuse F42 in Control
temperature Temperature transmitter TT401-2 cabinet to see what circuit
missing transmitter TT4012. malfunction. caused the fuse trip.
(TT4012) Parameter: N/A
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.
3. Use the circuit diagram to
locate the component or find
the reason that caused the fuse
2.1
31
Control system
32
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W116 AOT [x]: AOT Trigger: Level sensor Delay: Set in Signal missing or 1. Check fuse F42 in LDC to see
fluid level LS201-29. parameter p215. sensor LS201-29.x which circuit that caused the
signal missing Parameter: N/A malfunction. fuse trip.
(LS201-29).
2. Check relay KS02.
3. Use the circuit diagrams for the
LDC to check the fuse setting,
adjust according to figures in
circuit diagram if necessary
and reset fuse.
4. Use the circuit diagrams for
the LDC and AOT reactor to
locate the component or find
the reason that caused the fuse
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W117 AOT [x]: AOT Trigger: Level sensor Delay: Set in No fluid in AOT 1. Control that correct valves
fluid missing LS201-29. parameter p215. reactor. are opened for current
(LS20129) in Parameter: N/A process. See Detailed process
manual mode Comment: The AOT description in chapter 3.
reactor is shut down. Operating instructions and
Prevents start of LPS control system description.
(UV lamps) in manual
mode. 2. Check that the flow is equal
through all AOT reactors and
that the AOT.x is not clogged.
3. Restart the process from the
beginning.
W118 AOT [x]: CIP Trigger: Level sensor Delay: Set in No fluid in AOT 1. Check that valves V320-2,
flow missing LS201-29. parameter p215. reactor x. V320-4.x, V321-4 and 321-2.x
(LS201-29). Parameter: p208 LS201-29.x is open and close correctly.
indicating dry
2. Check that pump P320-1
condition.
2.1
33
Control system
34
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
Too low level in CIP Refill the tank with CIP liquid. See
tank. instruction Change and refill CIP
liquid in chapter 7. Service manual.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W119 AOT [x]: No Trigger: Level sensor Delay: Set in No liquid in 1. Check that pressure flushing
freshwater LS201-29. parameter p215. AOT reactor x. water in pipe 310 is according
filling in AOT Parameter: p216 LS201-29.x is to requirements in chapter 6.
(LS201-29). indicating dry Installation description and
List of alarms and warnings
35
Control system
36
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W120 AOT [x]: AOT Trigger: Level sensor Delay: Set in Fluid in AOT reactor Restart the process from the
was not drained LS201-29. parameter p215. x. LS201-29.x beginning.
(LS201-29). Parameter: p200 is indicating wet
condition.
Control system
W122 AOT [x]: Fuse Trigger: LDC cabinet Delay: 1 sec. Fuse in LDC has Check fuse F4243 in LDC cabinet
tripped in LDC for AOT tripped or has been to see what circuit caused the fuse
cabinet. Parameter: N/A switched off. trip. Check according to bullets.
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W126 AOT [x]: MCB Trigger: LCD x-1 Delay: 1 sec. Motor circuit breaker 1. See LPS alarms in section
tripped in LDC Parameter: N/A (MCB) for an LPS in Lamp power supply (LPS) on
List of alarms and warnings
W128 AOT [x]: LDC Q117. Delay: 5 sec. Motor circuit breaker Check Q117 in LDC.
cabinet fan (MCB) F1 in control
alarm cabinet has tripped
or has been switched
off.
2.1
37
Control system
38
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W129 AOT [x]: LDC Trigger: Water Delay: 5 sec. Leakage in cooling Repair.
cabinet water sensor LS below water piping.
alarm. heat exchanger in Dry wet areas in the cabinet.
LDC. Remove the sensor and dry it with
Control system
W130 AOT [x]: LPS Trigger: Lamp Delay: 2 sec. LPS malfunction. Check LED indication on the LPS
sum alarm. power supply in AOT that triggered the alarm. See LPS
Number of broken
reactors LDC. alarms in section Lamp power
UV lamps exeeds
Parameter: N/A supply (LPS) on page 50.
number set in
parameter p213. Check which lamps that are broken
in column Lamp OK in page 4.9
LPS overview.
W131 AOT [x]: UV Trigger: Lamp power Delay: 1 sec. One or more UV lamp Check which lamps that are broken
system failure. supply. is broken. in column Lamp OK in page 4.9
Too many failed Parameter: p213. Comment: AOT LPS overview.
lamps. reactor is deactivated.
Change according to instruction in
chapter 7. Service manual.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W132 Estimated UV Trigger: AOT reactor Delay: 1 sec. Lifetime for UV Recommended to change all lamps
lamp lifetime lap time. lamps are too after 3000 hours of operation.
exceeded. Parameter: p218. exceed according
to estimated lifetime Change according to instruction
in parameter. Replace UV lamp and quartz
sleeve in chapter 7. Service
manual.
A137 AOT [x]: High Trigger: TS201-60 Delay: 1 sec. No flow in AOT See W100.
List of alarms and warnings
39
Control system
40
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
connection. is according to electrical
drawings.
Check that all electrical
connections are OK and that
Control system
A138 AOT [x]: PLC Trigger AOT reactor Delay: 2 sec. Error in module. Check the LED error indication for
error in LDC x. the electronic modules in the LDC.
cabinet. Parameter: N/A Comment: AOT See section I/O system and X20
reactor is deactivated. modules on page 57.
W140 CIP schedule Trigger: Control Delay: Set in CIP not performed Control CIP status on page 1.3 CIP
timer elapsed system timer. parameter p117 and after operation. status in control system.
Start CIP! Parameter: N/A. p118.
Start CIP process.
Comment: CIP has not
been performed within
parameter set time limit
after (de)ballast.
W150 AOT [x]: Low Trigger: UV sensor Delay: 20 sec. Low UV intensity in Check water.
UV intensity QT201-50. AOT reactor.
(QT201-50) Parameter: p220 and Comment: The It is also possible to fill the reactor
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
in the event of system. Change if old. Lamps
malfunction. loose effect when maximum
runtime has been exceeded.
41
Control system
42
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W152 AOT [x]: UV Trigger: UV sensor Delay: None. See chapter 2. System overview,
intensity low. QT201-50. section Power optimization.
System flow Parameter: p221 Comment: The
reduced. and p237 warning is issued if
the UV intensity falls
below 484 w/m2. Power
is set to 100% for the
AOT reactor and the
flow is reduced.
W153 AOT [x]: UV Trigger: AOT reactor. Delay: None. See chapter 2. System overview,
lamp fail. System Parameter: p213 section Operation with broken UV
flow reduced. lamp.
2
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W161 AOT [x]: LPS Trigger: LPS Delay: 1 sec. Faulty connection of Check the three cable connectors
communication Parameter: N/A electricity or signal on the LPS .
error. AOT cable.
shutdown.
Wrong LPS setting. Check that the DIP switches
are correctly set for every LPS.
See chapter 4. Parameters,
section Lamp power supply (LPS)
parameters.
List of alarms and warnings
W162 AOT [x]: Trigger: None. Delay: None. Motor circuit breaker Replace.
Circuit breaker Parameter: p239 (MCB) is broken.
communication Warning is active
error. if parameter p239 Faulty modubus Check modubus cable W1 and W2.
Enable circuit breaker signal cable.
data is activated.
W163 AOT [x]: Lamp Trigger: LPS in AOT Delay: 20 sec. Broken UV lamp. Change according to instruction in
error feedback reactors LDC. chapter 7. Service manual.
from LPS. Parameter: N/A Comment: No lamp
feedback when it is Faulty connection of Check UV lamp power cable.
requested to be started UV lamp cable.
by the LPS.
W164 AOT [x]: LPS Trigger: LPS in AOT Delay: 20 sec. Faulty LPS. Check page 4.9 LPS power
error feedback reactors LDC. overview and LED indication on the
2.1
from LPS. Parameter: N/A Comment: No LPS LPS that triggered the alarm. See
feedback when it is LPS alarms in section Lamp power
requested to star its supply (LPS) on page 50.
lamp. AOT reactor is
deactivated If the power is on but there are
no indication, the LPS is probably
broken.
43
Control system
44
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W165 AOT [x]: LPS in Trigger: LPS in AOT Delay: 1 sec. One or more of the Check page 4.9 LPS power
fault state. reactors LDC. below: overview and LED indication on the
Parameter: N/A Comment: AOT LPS that triggered the alarm. See
reactor is deactivated. Air temp fault LPS alarms in section Lamp power
Control system
W170 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
2
Parameter: N/A
W171 Valve error Trigger: Limit switch Delay: 15 sec. See possible cause
(V20120) GS20120. for A17.
Parameter: N/A
W180 LDC ring Trigger: LDC. Delay: None. Faulty connection of Check that the power link (LAN)
redundancy signal cable cable from the control cabinet (in a
error Parameter: N/A loop to all LDCs) and back is OK.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
45
Control system
46
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W306 Filter differential Trigger: Pressure Delay: 2 sec. Filter is clogged. Backflush manually from control
pressure too transmitter PT201-71 system. If not sufficient, clean the
high and PT201-72. filter according to instruction in
Parameter: p301, chapter 7. Service manual.
p314.
Valves connected Make sure that the two valves
to filter pressure connected to the filter differential
transmitter closed. transmitter are open.
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
damaged.
W308 Filter pressure Trigger: Pressure Delay: 30 sec. Signal missing 1. Check fuse F42 in LDC to see
signal missing transmitter or component which circuit that caused the
(PT201-71) PT201-71. Comment: Alarm malfunction. fuse trip.
Parameter: p314. deactivated in Standby.
2. Use the circuit diagram to
check the fuse setting, adjust
according to figures in circuit
diagram if necessary and reset
fuse.
3. Use the circuit diagram to
locate the component or find
the reason that caused the fuse
trip and attend to it.
4. Check cables to PT201-71. See
2.1
47
Control system
48
2.1
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W314 Backflush failed Trigger: Hydac filter. Delay: 15 sec. See W308.
to start (timeout). Parameter: p314.
A315 Diff pressure too Trigger: Pressure Delay: 20 sec. See W306.
high. Automatic transmitter PT201-71
shutdown. and PT201-72. Comment: Pressure
Parameter: p300. transmitters indicates
pressure higher than
set in p300.
2
W501 Log box error Trigger: Log box Delay: 10 sec. Faulty cable Check connections and cable for
(optional). connection. power cable (W10) and Ehternet
Parameter: p500. cable (W104) between Control
cabinet and Log box.
Fuse in the log box Check fuse F02 and F03 in the log
has tripped or has box.
been switched off.
List of alarms and warnings
Alarm Alarm text Trigger / Parameter Description Possible cause What to do?
ID
W502 External bypass Trigger: Log box Delay: 10 sec. See A33.
49
Control system
2.2 Lamp power supply (LPS) 2 List of alarms and warnings
5 LPSledG
5 LPSledY
LPS temperature too high (> 50 C).
LPS fan faulty.
Lamp error. Possible causes:
5 LPSledR
Two lamp ignition failures.
Broken UV lamp.
Loose cables to UV lamp.
Lamp on.
5 LPSledB
5 LPSledB2
Faulty DIP switch setting on one or more LPS. This fault occur after a 10 seconds
delay after start.
Voltage on the fail safe is missing.
4FlowT_Alarm
Alarm time is displayed as time elapsed since the error occurred, and is showed as days, minutes
and hours.
Alarms and status are displayed in two lists, accessible from the Service mode screen in the flow
transmitter:
Yes: Go to step 5.
No: The tranmsitter is defect. Change.
Yes: Go to step 7.
No: Go to step 6.
7. The transmitter is OK. Check the following: Settings, application, installation, sensor, earthing,
connections etc.
8. The transmitter still not OK? Change settings according to chapter 4. Parameters, section
Flow transmitter parameters.
9. If the problem cannot be detected or corrected, the transmitter must be replaced according to
the instruction Mount flow transmitter. Note that it is not necessary to reset parameters in the
new transmitter. The settings are stored in the Sensorprom unit. When the new transmitter is
replaced, settings are downloaded automatically.
Buttons used:
2. To enter password (1000): Press Padlock. (A line appears under th e first zero.)
- Press Change to change the first 0 to 1.
- Press Padlock to set the value.
- Result: The Basic settings menu appears after two seconds.
4. Press Padlock, and then Forward until the Error pending menu appears.
7C Indicates flow Unde- N/A. Measuring flow Select empty pipe cut-off
with no flow fined sensor (pipe)
in pipe empty
Red Blinking Error: Internal sensor error or sensor Replace the component.
corroded.
All modules are identified on the front, for example X20 DO 6529 in the illustration below. To the
right, the stat indication LEDs are visible, for example r, e, X, I in the illustration below.
5X20
NOTE
Note that all status indications are not valid for all modules.
The meaning of a status indication might vary for some modules. These variations are specified
in the Description column.
Module BC0083, CP3585 and IF1082-2 are described in separate tables below the generic
table.
The table contains the following columns and information:
Module BC0083
Module CP3585
Module IF1082-2
The status/error light is a green/red dual LED. The interface can be operated in two moedes: Either
in Powerlink V mode or as an Ethernet TCP/IP interface. Status light depends on mode. For
TCP/IP mode, only SE green is valid.
Module DI9371
This section contains problems that can occur, but is not indicated by an alarm.
1A The system does not start. Main breaker Q1 on control Turn on the breaker and measure that incoming 24 V DC to
The control panel does and LDC cabinet turned off, the control panel is present.
not light up. or power not connected to the
control panel.
General problems
Fuse F42 tripped. 1. Check fuse F42 in control cabinet to see what circuit
caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3. Use the circuit diagram to locate the component or find the
reason that caused the fuse trip and attend to it.
Fuse F41 in control cabinet 1. Check fuse F41 in control cabinet to see what circuit
tripped. caused the fuse trip.
2. Use the circuit diagram to check the fuse setting, adjust
according to figures in circuit diagram if necessary and
reset fuse.
3
Control panel error due to Let the panel dry and try again.
damp.
List of problems and solutions
1B Control panel is not Abnormal operating condition. 1. Restart the control panel: Cut the power by removing the
displaying a normal page. power cable at the back of the control panel. Wait 30
seconds, and reconnect the cable again.
2. Restart the entire PureBallast system: Cut the power by
switching of the main breaker on the control cabinet. Wait
30 seconds, and switch on the main breaker again.
3. If panel is not OK, it is probably broke and needs to be
replaced. Replace the component.
List of problems and solutions
HMI software problem Re-load the HMI software according to the software Release
note.
1C PureBallast can not be Communication is broken See the What to do column for alarm A93.
controlled or monitored between ISCS and PLC.
from the ISCS graphical
user interface via the
remote interface (optional)
5 PanelCommunicationError
These messages can appear alone or in combination. The message does not appear in remote control panels (option).
67
68
3.1
Problem Description Possible cause What to do?
ID
3.2 Filter
Pressure transmitters
PT20171 and PT20172 Error with the pressure gauge Dismantle the component and inspect/attend to.
may be faulty. electric switches.
Valves for air pressure to valve Open the valve (ball cock) connected to V309-1.
V309-1 are closed.
5B Excessive backflushing The filter house is not properly Deaerate using the deaeration valve V201-50 on the filter lid.
or long backflushing deaerated.
sequences (general)
Damaged filter . Check filter for damage. Replace if necessary.
Large obstructions have Open the filter and remove the obstructions. See chapter 7.
entered the filter. Service manual, section Filter.
3.3 CIP
Air pressure too low due to Adjust setting with the manual valve under the valve block on
incorrect setting on valve block the CIP module.
on CIP.
The diaphragm in the CIP pump Examine the pump. See chapter 7. Service manual, section
is broken. Repair CIP pump.
Pump is clogged. Examine the pump. See chapter 7. Service manual, section
Repair CIP pump.
6B Too high consumption of Leakage in the CIP tank, CIP Locate leakage and attend to.
CIP liquid (> 1 cm/AOT pump, pipes or AOT reactor.
reactor cycle).
6C CIP liquid is not returned Insufficient pump capacity 1. Increase airflow to the pump to increase pump capacity
to CIP tank. (P321-5). with the manual valve under the valve block on the CIP
module.
2. Check that pump P321-5 is functioning correctly. See
problem 6D6I in this chapter.
6D CIP pump does not run The air pressure is to low Examine the pump and attend to problem. See chapter 7.
Service manual, section Test CIP pump.
The air connection is
blocked
Muffler is blocked
Air valve is defect
Dirt in the pump chamber
Diaphragm breakdown
List of problems and solutions
6E CIP pump runs irregularly Valve balls are blocked Examine the pump and attend to problem.
Sealings are defect in air
valve or center block
Diaphragm breakdown
6F Insufficient CIP pump Suction connection blocked Examine the pump and attend to problem.
suction or not tight.
Muffler is blocked
Valve balls are blocked or
damaged
List of problems and solutions
6H CIP pump leakage Screws on the housing not Tighten the screws.
properly fastened
73
CIP
3.4 Valve V2018 3 List of problems and solutions
8A Signal change has no effect on Faulty air supply Check air supply to the valve and tubing to the actuator.
the actuator position See chapter 7. Service manual, section Proportional
valve for instructions regarding the proportional valve.
8B Signal change results in actuator Connection or signal problem Check coupling between proportional valve and
running to end positions actuator.
Check input signal.
8C Signal and positioning problems. Inaccurate positioning. Adjust position sensor. See chapter 7. Service manual,
List of problems and solutions
75
Chapter: 6. Installation description and drawings
System manual PureBallast 3.1 Flow 1000
3 Technical data 11
3.1 PureBallast system 11
3.2 PureBallast components 12
3.3 Working pressure and pressure drop 14
3.3.1 Working pressure during ballast operation and
during backflush 14
3.3.2 Pressure calculation 14
4 Installation guidelines 17
4.1 Preparations and conditions 17
4.1.1 Safety information 17
4.1.2 General installation requirements 17
4.1.3 Installation of components supplied by shipyard 18
5 System interfaces 25
5.1 Remote control panel integration
(optional) 25
5.2 Remote interface integration (optional) 26
5.2.1 Communication between PureBallast PLC and
remote interface 26
5.2.2 Directory of addresses 28
3
5.3 Power management system integration 46
5.3.1 Overall power request process 47
5.3.2 Power steps and power signals 47
5.3.3 Power management installation 49
6 Start-up procedures 55
7 Drawings 57
7.1 Graphic symbols used in drawings 58
7.2 General drawings 59
7.2.1 Flow chart 59
7.2.2 Connection list 60
7.2.3 Electrical system layout (2 pages) 66
7.2.4 Instrument air distribution 68
7.2.5 Quality specification / Instrument air 69
7.2.6 Quality specification / Fresh water 70
7.2.7 Quality specification / CIP liquid 71
7.2.8 Safety data sheet / CIP liquid 72
4
7.4 Electrical drawings 99
7.4.1 Control cabinet / Interconnection diagram (7 pages) 99
7.4.2 Control cabinet / Circuit diagram (22 pages) 106
7.4.3 Control cabinet / Cable list 128
7.4.4 Lamp Drive Cabinet (LDC) / Interconnection
diagram (2 pages) 129
7.4.5 Lamp Drive Cabinet (LDC) / Circuit diagram (16
pages) 131
7.4.6 Lamp Drive Cabinet (LDC) / Cable list 147
7.4.7 AOT reactor and LDC / Lamp power cable 148
7.4.8 AOT reactor / Interconnection diagram (2 pages) 149
7.4.9 AOT reactor / Circuit diagram (3 pages) 151
7.4.10 AOT reactor / Cable list 154
7.4.11 Remote control panel (optional) / Circuit diagram 155
7.4.12 Pump cabinet (optional) / Layout 156
7.4.13 Pump cabinet (optional) / Circuit diagram (2 pages) 157
7.4.14 Pump cabinet (optional) / Interconnection diagram 159
7.4.15 Pump cabinet (optional) / Cable list 160
5
1 Introduction
This chapter contains information about how the PureBallast system is to be installed and drawings.
The information is presented as installation guidelines per component, relevant standards and
drawings. The chapter is opened with a summary of the main technical data.
Enter vessel specific information in the table below. This will facilitate reading information and
drawings in this document, since some drawings include information for all system sizes /
dimensions, and the document contains information for options only used by on some vessels.
Data Value
This section states technical data for the complete PureBallast system and for individual
components. In some cases references are given to data in drawings included in this chapter.
Water requirements See section Quality specification / Fresh water on page 70 and data
for different components in the Connection list on page 60.
Sea water: Used for cooling UV lamps in the AOT reactor during
start-up.
LT (low temperature) fresh water: Used for cooling the lamp drive
cabinet (LDC) during operation.
Fresh water: Used for flushing and filling up of AOT reactors after
treatment.
Salinity of water to be PureBallast water treatment system with Filtrex filter can be used in
treated all salinities.
System flow Flow range ballast (m3/h): 195 Flow range deballast (m3/h):
1000 100 1000
Power consumption Maximum power consumption (kW): 101. Power factor: 0.95.
Based on maximum:
100
Note: PureBallast only use the power needed for efficient
treatment. During operation, the UV lamps are lit to between
50 and 100 % of their capacity, depending on measured water
transmittance.
1 kW (Control system including PLC, 24 V feeding, CIP motor
supply, filter motor supply)
UV intensity power The system have been tested and found to give full treatment of the
limit ballast water when the measured UV intensity is above 252 w/m2.
AOT reactor Pressure drop See data for different components in Connection
list on page 60.
Tank volume 250 liters. Note: Total tank volume is 300, but
shall only be filled to max 250.
Remote control panel Dimensions See Control panel / Dimension drawing on page
(optional) 98 and on Control panel integration page 25.
When the differential pressure reaches a parameter set limit (default is 0.50 bar), a backflush
operation is started automatically. To secure sufficient backflush flow, the pressure at backflush
must be at least 1.50. For detailed information about backflush, see chapter 2. System description,
section Filter.
6 Working_Pressure_Filtrex
During ballast operation, the ballast water flow goes through the AOT reactor which gives a
maximum pressure drop of 0.70 bar (not including vessels piping), as described in the table below.
Note that the total pressure drop only includes the PureBallast components, not the vessels piping
before the first PureBallast component (Q201.1 ) or after the last (V2018).
AOT 0.20 bar pAOT: 0.20 bar (0.02 MPa) including PureBallast valves. Piping
reactor is not included, since it is installation specific.
Note that 0.50 bar is the default limit value for parameter p305
(Backflush trigger), which defines maximum allowed differential
pressure over the filter. Note that this parameter can be adjusted,
but only by Alfa Laval during commissioning.
Total 0.70 bar 0.70 bar (0.06 MPa) not including piping.
During backflush, the ballast water flow goes through the filter and AOT reactor, and the backflush
discharge flow goes through the filter and pipe 309.
A pressure calculation must be done to secure sufficient backflush flow in pipe 309 and to secure
that the ballast water pump can overcome the pressure drop (see table below). Note that the
calculated total pressure drop only includes components from the PureBallast inlet valve V2012
to the backflush over board valve.
Backflush 1.0 bar Difference between filter inlet 201 and filter backflush outlet
differential 309.
pressure
P309 Calculated The pressure drop for pipe 309 is installation specific and must
be calculated.
To ensure that pbackflush is 1.5 bar, the total pressure drop must be calculated according to the
formula below:
This section covers requirements for installing different components of the system.
NG
WARNI
!
Read chapter 1. Safety.
Installation must be done by a fully trained professional installer.
Damages related to transport and installation should be recorded.
This version of PureBallast is not EX proofed, and must not be installed in areas where an
explosive atmosphere may occur.
The PureBallast must be installed in a machinery space on the vessel (engine room, pump
room etc).
The Installation guidelines in this section must be followed.
Installation requirements given in the dimension drawings must be followed. See section
Drawings in this chapter.
Components must be properly suspended and supported.
There must be sufficient access to maintain the components. Access area is defined in the
dimension drawings.
Installed component must not amplify vibrations to or from the hull.
All piping connected to the PureBallast components (AOT reactor, filter and CIP module shall
be properly self supported. No load shall be transferred to or from any major components.
All components must be installed and marked as specified in dimension drawings, flow charts
and other drawings included in this manual.
- General drawings overall and principle information for system layout (pipes, components,
electricity, air and water).
- Dimension drawing detailed component information (dimensions, sizes etc).
- Electrical drawings detailed electric information (circuit diagrams, cable lists etc).
Connection list
Quality specification for water
Quality specification for instrument air
Installation guidelines
Electrical drawings
The AOT reactor must be fixated at the bottom and supported at the top to carry the weight
of the component. Use the upper and lower fixing holes (1) in the support structure to fixate
the component to the steel construction of the hull. If this is not enough, completing stays has
to be made. There are four fixing holes on each side at the bottom and four at the top, after
the lifting beam has been removed.
6 AOT installation
Prepare the inlet piping first. Then mount the AOT reactor onto the inlet flange and secure it.
Finally install the outlet piping onto the top of the AOT reactor.
We recommend that the installation of the reactor is planned to be supported by its lifting point
until the units lower part is completely secured to the foundation and inlet flange.
No fixtures should be attached to the reactor housing by welding, since this will damage or
distort the reactor, and potentially affect the biological performance of the component.
The AOT reactor must be earthed. The earth nut is indicated as 791 in the dimension drawing.
4.3 Filter
Follow the guidelines below when installing the filter.
Filter must be placed on a firm level surface. The legs can be bolted or welded in place on
a steady foundation.
Pipe 309 (filter backflush overboard line), with its valve, must be correctly connected.
The component must be earthed. The earth nut is indicated as 791 in the dimension drawing.
The filter motor must be mounted, if not mounted at delivery. See chapter 7. Service manual,
section Mount filter gear motor for instructions.
The electrical cable is connected from the control cabinet to the CIP valve block. See chapter 7.
Service manual, section Connect electrical cables to valve block.
The component must be earthed. The earth nut is indicated as PE bolt in the dimension
drawing.
The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation.
The deaeration pipe after deaeration valve V571-1 must reach approximately 2 meters higher
than valve V321-2 at the AOT reactor to avoid water spillage during CIP process. It is
recommended that the deaeration pipe is led to a scupper to collect eventual (minor) water
spillage.
Connections to the flanges must be made so that the connection is not exposed to any moment
or load. This is particularly important when connecting the plastic flanges.
Max tightening torque for bolts on flanges: 20 Nm.
NOTE
System interfaces (optional) must be integrated according to section System interfaces on page :
Cables General
Electrical cables must be properly routed and supported according to applicable regulations.
Earth cables must have a cross-section large enough in relation to the supply cables from the
vessel. Otherwise the equipment might be damaged during welding.
Cable entries to cabinets must be sealed, using the built in cable glands. See instruction
Cable glands in chapter 7. Service manual.
Cabling shall be done according to specification in Electrical system layout on page 66, and
the electrical drawings. This includes cable routing, cable types and cable marking to simplify
identification and fault finding.
Power cables shall be separated from signal and bus cables. Distance between them reduces
electrical noise transfer.
- If placed on a cable rack, place power and signal cables on opposite sides.
- If cables are routed in tubes due to narrow space, the power and signal cables shall be
routed in separate tubes.
EMC: Cables shall be peeled down to the cable shield. The shield must be connected to earth.
Cabinets General
The cabinets maximum distance (cable length) to the AOT reactor: 150 meters.
The component must be placed on a firm level surface. The legs of the component can be
bolted or welded in place on a steady foundation. It is possible to detach the cabinet from the
bottom frame to facilitate installation. The cabinet shall also be attached to the bulkhead using
the attachment bolts on the top of the cabinet.
Lamp power cables W211A-D (included in scope of supply) shall be connected from X3 in
LDC to X20:B in junction box on the AOT reactor. (Cables from junction box to lamps are
pre-assembled.)
Note: Lamp power cable dellivered from Alfa Laval must be used.
Power cable W201.1 to be connected to main switch board: Max Icu 50 KA.
Signal cables W210A and B to be connected from X1 in LDC to X20:A in junction box on the
AOT reactor. Cables from junction box to components are pre-assembled.
The lamp power cable should not be winded. If it is to long, cut it before it is connected.
It is possible to dismount the doors during installation: Slide the red catch on the hinge
backwards and release the locking mechanism.
Control cabinet
The ballast water flow direction must be according to the arrow on the flow sensor.
The flow transmitter must be mounted on the flow sensor pipe. It is not pre-assembled from
factory. See chapter 7. Service manual for instructions.
A drain solution (not part of Alfa Lavals scope of supply) must be attached to safety valve
RV201. The valve shall be drained to a scupper, with a solution which always allows water to
be drained from the valve. See Pressure monitoring device / Dimension drawing.
Inlet and outlet pipes must be correctly connected. They must also be pressure approved by a
classification society or equivalent, or be tested under supervision of a classification society
and/or at the ship yards pipe shop etc.
Pipes shall be designed to carry the weight of the component and media.
A bypass valve (optional part of Alfa Lavals scope of supply) must be installed. The bypass
valve (V212-31) shall be connected to the the vessels ISCS, to enable control of the valve, and
PureBallast control system to indicate valve position. See Control cabinet / Interconnection
diagram on page 99.
If PureBallast can be bypassed using other valves (apart from V212-31), status signals from
them must be connected to the control cabinet. All bypass cases must be logged.
Three additional bypass valves can be handled, identified as additional bypass valve 1, 2 and 3.
If more valves are used, they must be connected in series, which means that they are handled
as one regarding alarms and logging in PureBallast.
Signal cables for additional bypass valves are installed according to section External component
signal integration on page 50.
The yellow position indicator on actuators must be in line with the valve throttle. For pipes with
dimension 400, the red position indicator on the actuator coupling (see drawing) must also be in
line with the throttle. The position indicator must be in line with the pipe when the valve is open.
If not correct, change according to instruction in chapter 7. Service manual for instructions.
Valves shall be opened when installed. This is important to avoid that the rubber gaskets are
squeezed and damaged during installation.
Valve actuators pneumatic lines must be correctly connected and supported. See chapter
7. Service manual for instructions.
Valve actuators electric connectors must be correctly connected.
Sampling device Q201.1 and Q201.2.
- If delivered by Alfa Laval: Must be mounted with the pin pointing in the flow direction (see
drawing on page 92).
- Flanges for connecting the sampling devices must be installed before the pipe is coated.
Components shall be connected to air supply that meets the requirements or the Quality
specification / Instrument air 69. Air shall always be connected.
This section covers guidelines for how to install and integrate the following, if used:
Remote control panel is mounted according to according to drawing Remote control panel /
Dimension drawing. Note the clearance area.
Mounted at an optional location.
Communication cable (W501) between the remote control panel and control cabinet can be
either Ethernet or fiber. Cable requirements and connection points below:
- Ethernet cable Type: Cat 5e (or better), shielded. Max length: 100 meters.
One remote control panel: From terminal X2 in remote control panels to terminal X13 in
the control cabinet. Two remote control panels: From terminal X2 in second remote
control panel to either switch SW1 in control cabinet or to switch SW1 in the first remote
control panel.
- Fiber cable Type: Multi-mode fiber cable with LC connector. We recommend a cable with
four or more cores are used to have spare cores if one is broken. Max length: 500 meters.
From remote control panels switch SW1 to switch SW1 in control cabinet.
See Remote control panel / Circuit diagram on page and cable list.
Communication settings must be done according to instruction in chapter 3. Operating
instructions and control system description, section Set control panel IP address and Set
remote control panel communication.
PureBallasts PLC communicate with the vessels ISCS via the remote interface. Data is sent to
and from dedicated addresses via modbus. Data can be commands, values (sum of bits), alarms
and status information. The data is then presented in the ISCS according to the vessels graphical
standard. It is possible to present all information (all addresses) or a selection. Data is sent as
binary code, with exception for time, which is sent as hexadecimal code.
Cable W602 to be connected from connection terminal (X15) in control cabinet to ISCS.
Modbus connection from ISCS to PureBallast connection terminal X15 in the control cabinet.
Connection standard: RS485 (or RS422, not described in electrical drawings) according to
Control cabinet / Interconnection diagram. Recommended max length: 500 meters.
Implementation of remote interface signals in the ISCS according to the guidelines in this section.
Communication settings must be done according to chapter 3. Operating instructions and
control system description, section Set remote interface communication.
Parameter p132 and p128 must be set in the control system.
Reference information about the logical flow of the PureBallast processes can be found in chapter
3. Operating instructions and control system description, section Detailed process description.
Modbus settings
The ISCS modbus RTU server data shall be set according to the table below:
Slave ID 10 N/A
PureBallast
is slave
and ISCS is
master.
The following terms are used to explain the signals in the tables below:
Address/Bit Address and bit is written as Address:Bit, for example 73:14. Bits are right
aligned in the Address column.
The start address is 40000. Individual addresses are shortened to the last two
or three digits, for example 73 (which actually is 40073 in the program code).
Function Name of the function. The name corresponds to the text used in the
PureBallast control system HMI. Parenthesis gives reference to the control
system page where the information is used/displayed. For further information
about respective piece of information, see chapter 3. Operating instructions
and control system description.
Description Additional information, for example specific conditions that must be met before
a command can be sent.
Used Mark all implemented signals. This list should also be sent to Alfa Laval for check
during commissioning. Only used signals should be tested.
OK Mark all signals that passed the test. Signal from ISCS should give correct reaction
in page 4.5. Signal to ISCS should give intended reaction in ISCS. Signal OK also
includes correct scaling according to section Test values sent to ISCS.
The addresses below are used to send commands and status information from ISCS to PureBallast.
01 Commands
Condition: All signals for 01 must be high until PureBallast return an accept
or reject signal (see 70).
Bit 6 Ack all alarms and Command: Acknowledge all alarms and warnings.
warnings (2.1)
Condition: Signal shall be high so long it can be
assumed that it is received by the PureBallast,
considering the installation specific conditions.
Bit 7 Apply new flow (1.1 Confirm activation of new flow selected using
and 1.2) address 03 (Selected flow).
02 Feedback
3= 3000 m3/h.
Bit 04 Power granted 14. Bit 13: Power granted for the number of AOT
reactors sent.
The addresses below are used to send data from PureBallast to ISCS.
54 Number of AOTs ready Number of AOT reactors that are ready for use
(1.2) in process.
56 Current max flow (1.1, 1.2) Maximum flow in m3/h for process, based on
number of selected AOT reactors and filter
capacity.
59 Remaining time for CIP Number: Total estimated remaining time (hours)
(hours) (1.3) for all CIP sequences and filter preservation.
61 Remaining time until CIP Number: Hours before CIP must be performed.
req. (hours) (1.3) Displayed per AOT reactor.
62 Remaining time until CIP Number: Minutes before CIP must be performed.
req. (min) (1.3)
For details, see 61.
The addresses below are used to send commands and status information from PureBallast to ISCS.
Example of data: Process mode (standby, ballast, CIP), acceptance of command from ISCS, and
request to ISCS to start ballast pump.
/ Bit
70 Command status
Bit 7 Sum alarm Common alarm indicating that one (any) alarm is
active. Alternative to implementation of individual
alarm signals and hardwired common alarm.
Functions in the same way as hardwired external
signal Common alarm.
Bit 11 AOT cool down After process, the UV lamps in the AOT reactor
must bee cooled down. During coolin down, no
process can be started.
Status:
1=AOT reactor is cooling down..
0=AOT reactor is not cooling down.
71 Commands
Bit 0 Start ballast water pump Request to ISCS to start ballast water pump:
(1.1) 1=Request to start.
0=Request to stop.
Bit 1 Open overboard valve (1.1) Request to ISCS to open overboard valve:
1=Request to open.
0=Request to close.
72 Process mode (1.1, 1.3) Status. Number sent indicates system mode:
0=Booting
1=Standby
2=Ballast
3=Deballast
4=CIP
5=Emergency stop
6=Manual mode
8=Stripping
73 Sub process mode (1.1, 1.3) Status. Number sent indicates system mode:
0=None
1=Start-up ballast
2=Full ballast
3=Backflush
4=Pause
5=Stop with backflush
6=Increasing ballast flow capacity
7=Decreasing ballast flow capacity
8=Start-up (deballast and stripping)
9=Full deballast
10=Pause deballast
11=Stop (deballast and stripping)
12=Increasing deballast flow capacity
13=Decreasing deballast flow capacity
14=AOT reactor drain 1 Sea water
15=AOT reactor fill 1 Fresh water
16=AOT reactor drain 2 Fresh water
17=CIP
18=AOT reactor fill 2 Fresh water
19=Preservation filter Fresh water
20=Heeling mode
21=CIP drain
22=Stop (If ballast process is stopped before
mode Full ballast, no backflush is performed.)
23=AOT cool down.
24=Full stripping.
75 Power request [14] (1.4) Only relevant if PureBallast is integrated with the
vessels power management system.
Bit 04 Power request [14] (1.4). It is only necessary to use signals (bits) to cover
the need for power request. This is defined by
the number of AOT reactors, alternatively use
of common power.
76 Power running [14] (1.4) Only relevant if PureBallast is integrated with the
vessels power management system.
The addresses below are used to send status information for components to ISCS.
/ Bit
80 Main valve status (1.1, 1.3 and popups for AOT reactor and filter)
The tables below lists all alarms and warnings sent from PureBallast to the ISCS. Each alarm is
defined as a specific bit. The bit is set to 1 when the alarm is activated. The alarm IDs refer to alarms
described in chapter 5. Alarms and faultfinding, where texts to be displayed in ISCS can be found.
Example: If data at address 40902 is 000010000000100, this means that alarm W04 and warning
A33 are active (bit 2 and 10).
Common alarms and common warnings (900 and 901) indicate that there exist a common alarm
for the area or component specified.
Example of alarms and warnings: Process flow too high, valve error, component signals missing.
Bit
10 A33 W82
11 A35 W83
14 A49 A93
15 A50 W95
The addresses below are used to send status information, alarms and warning for AOT reactors
and LDC to ISCS.
Status information
Addresses for data regarding AOT reactor and respective LDC are separated in number series to
distinguish information for individual AOT reactor/LDC, if more than one.
Example of data: Status for AOT reactor and LDC and their components, for example temperature,
UV intensity and valve status.
/ Bit
Bit 1 AOT ready (1.2) Status: AOT reactor is ready, which means that
there exist no critical alarms or warnings for the
AOT reactor (110:5, 120:5 and 130:5 = 0).
0=Not ready.
Bit 2 AOT selected (1.2) Status: AOT reactor selected for process by
operator. In PureBallast, the AOT reactor is
visible in the list AOT reactors selected for
process in 1.3.
Bit 5 AOT sum alarm (1.2 and Status: Common alarm indication for AOT
AOT popup) reactor. The AOT reactor is not ready.
Bit 6 AOT sum warning (1.2 and Status: Common warning indication for AOT
AOT popup) reactor. If the warning is not critical, the AOT
reactor may have status AOT ready.
Bit 7 AOT CIP required (1.3) Status: CIP status for AOT reactor: 0=Not
required. 1=Required.
Bit 8 AOT CIP ongoing (1.3) Status: CIP status for AOT reactor: 0=CIP not
ongoing. 1=CIP ongoing.
Bit 9 AOT CIP error (1.3) Status: Error for AOT reactor during CIP process.
Bit 10 AOT cool down (1.1) Status: AOT reactor cool down.
112 / 122 / AOT LPS status 1 (4.9 and Status: Status per individual LPS in the AOT
132 AOT popup) reactor.
Status:
1=Lamp on. 0=Lamp off.
113/ AOT LPS status 2 (4.9 and Status: Status per individual LPS in the AOT
123/ AOT popup) reactor.
133
In AOT reactor 300 m3/h: Only bit 09 is used.
Status:
116 / 126 LDC air temperature (AOT Number: LDC air temperature in cabinet
/ 136 popup) indicated by TT401-2.
117 / 127 UV intensity (AOT popup) Number: UV intensity in AOT reactor indicated
/ 137 by QT201-50.
118 / 128 Power output (4.9) Number: Current LPS power consumption
/ 138 (50-100 %).
Alarms and warnings for individual AOT reactors and LDCs are separated into different number
series according to the list below:
Example of alarms and warnings: High temperature, fuse tripped, communication error for LPSs.
Bit
5 W111 W1831
11 W120 W160
12 W122 W161
13 W126 W162
14 W128 W163
15 W129 W164
The communication is either handled by the remote interface (if the option is integrated) or via
hardwires between the vessels ISCS and PureBallasts control cabinet. It is also possible to use
hardwire, even if remote interface is integrated.
Signals are defined to handle all combinations of power step (amount of power) and function
(request, grant and run). More than one signal can be sent (or received) at the same time to
achieve, for example step 1 and 2 to request power for 3 AOT reactors.
As an alternative, it is possible to use power step 4 (common) that always will be used, regardless
of the number of AOT reactors used for a specific process. The common power is defined as the
number of installed AOT reactor times the defined power consumption for one AOT reactor.
Note that It is only necessary to connect enough signals to cover the number of AOT reactors
installed on the vessel. If one AOT reactor is installed it is only necessary to connect step 1 for
request, granted and running.
After installation, the signals need to be tested. This is done by simulating signals from the control
system, page 1.4 Power request. See chapter 3. Operating instructions and control system
description, instruction Simulate power request.
Each signal that is used must be activated in the control system page 5.2 Main parameters 2.
Output indicates signal from PureBallast and Input indicates signal from ISCS.
Common alarm (strongly Output What: Output signal from PureBallast that there is an
recommended to be (any) active alarm. An alarm stops down ongoing process.
integrated)
How: Active alarm = Open circuit. If an alarm is already
present and a new alarm is issued, the signal will go low
for three seconds, and then be reactivated as high.
Common warning Output What: As common alarm, but for warnings. A warning is
a notification of status change or a problem.
External system stop Input What: Input signal to PureBallast to stop the system.
If extra buttons (not part of AL scope of supply) to stop
PureBallast are desired on board. The power is still on.
Heeling mode (internal Input What: Input signal to PureBallast to to enter heeling mode.
transfer) Equal to pushing the Pause button in control system.
Additional bypass 1 is Input What: Input signal to PureBallast that an external bypass
open valve (not part of Alfa Lavals scope of supply).
Request Open Output What: Output signal from PureBallast to request opening
overboard valves of relevant valves (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the valve are closed.
Relevant valves: 201, 309 and 403 and 404 (and 460.1
during CIP process). Note that the signal is mainly
intended for the valves apart from those leading to and
from pipe 201
Feed back Overboard Input What: Input signal to PureBallast to confirm that relevant
valve is open valves are open.
Request Start BW Output What: Output signal from PureBallast to request start of
pump ballast water pump (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the pump is stopped.
Feed back BW pump is Input What: Input signal to PureBallast to confirm that the
running ballast pump is started.
Request Start stripping Output What: Output signal from PureBallast to request start
pump of stripping pump (not operated by PureBallast). After
process is stopped, the signal goes low to request that
the pump is stopped.
Feed back Stripping Input What: Input signal to PureBallast to confirm that the
pump is running stripping pump is started.
LDC cooling water pump Output What: Output signal from PureBallast to request start of
(P401-1) the LDC cooling water pump for line 401. Pump P401-1
is used during ballast, deballast, stripping, pause and
heeling mode.
AOT cooling water pump Output What: Output signal from PureBallast to request start
(P403-1), for of the AOT reactor cooling water pump for line 403.
Pump P403-1 is used during start-up, ballast, deballast,
stripping, pause and heeling mode.
PureBallast running Output What: Output signal from PureBallast that a process is
running.
Input signals
Chosen input signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 99.
Output signals
Chosen output signals must be connected from the control cabinet according to Control cabinet /
Interconnection diagram on page 99. Output signals are connected via potential free relays.
The GPS communication must use protocol NMEA-0183, version 4.00 and should be connected to
module X20IF1030 in the control cabinet. The following settings must be used:
The GPS is integrated according to drawing Electrical cabinet / Interconnection diagram and
Electrical cabinet / Circuit diagram.
Serial: RS422
Baud rate: 4800 bps
Parity: None
Bits/characters: 8
Stop bits: 1
The position data shall be sent as messages according to RMC, GLL or GGA.
The actions below must be performed after installation, before system is put into operation. This
is important to avoid that the filter and the AOT reactor is damaged by material from the ballast
tanks or remainders from the installation. These actions shall be performed both for new builds and
retrofit installations.
Before the system is operated the first time the actions below must be done.
NOTE
All pipes leading to PureBallast must be well flushed to avoid that debris harm the filter or
AOT reactor quartz sleeves.
All ballast water tanks must be well cleaned before PureBallast is tested or put into operation.
This is valid both for new builds and retrofit installations.
First operation
During the first operation, the filter shall be bypassed, to avoid that debris harms the filter
elements.
We recommend that a strainer is used during the first operations, to avoid that debris harms
the system.
The first time a tank is stripped, PureBallast must be bypassed, to avoid that debris harms
the system.
This section contains drawings for the PureBallast system. It is divided into three main parts:
General drawings overall and principle information for system layout (pipes, components,
electricity, air and water).
Dimension drawing detailed component information (dimensions, sizes etc).
Electrical drawings detailed electric information (circuit diagrams, cable lists etc).
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8 Type approval and test result
summary
this section conains the type approval certificate for PureBallast toghether with a summary of the
test results from the land based and ship board tests.
6 Cert_Page_1
8 Type approval and test result summary 8.1 Type approval certificate (7 pages)
6 Cert_Page_2
6 Cert_Page_3
6 Cert_Page_4
6 Cert_Page_5
6 Cert_Page_6
6 Cert_Page_7
6 CertTest_Page_2
8 Type approval and test result summary 8.2 Test result summary (5 pages)
6 CertTest_Page_3
8.2 Test result summary (5 pages) 8 Type approval and test result summary
6 CertTest_Page_4
8 Type approval and test result summary 8.2 Test result summary (5 pages)
6 CertTest_Page_5
8.2 Test result summary (5 pages) 8 Type approval and test result summary
9 Shutdown and storage
This section describes requirements for decommissioning and storage. The rules must be followed
when the system shall be shutdown for a long period.
A copy of the decommissioning report must be placed inside the control cabinet. The report must
include all important information from the decommissioning, for example notes and information
about where to find stored components.
9.1 Decommissioning
Follow the process below to decommission the PureBallast system. Note that if there is a freeze
risk, the system must be completely emptied of water.
Disconnect the air supply to the CIP module. Use service valve if possible, otherwise plug
the air supply inlet.
Disconnect and drain the membrane pumps (P320-1 and P321-5). Rinse with fresh water
and reconnect the pump.
Protect pressure monitoring device etc. from mechanical damages. The following components
are recommended to be removed and stored safely: PT201-71, PT201-72, PT201-16, and
PI201-18.
Protect components equipped with circuit boards from condensation. Recommendations:
Every 3rd months, operate each valve by close/open exercise. This will keep the valves and
actuators in best condition.
Note that control valve V201-8 must be exercised manually at the same time as the IP201-7 is
removed. Use a wrench to apply appropriate torque.
This section contains information about how to handle PureBallast components during transport,
delivery and installation.
Always read and follow the documentation included in shipment of components and spare
parts regarding handling, safety and disposal.
Handle the delivery with care in order not to damage the equipment or cause personal injuries.
If the PureBallast system is stored before installation, make sure to store the components
according to the Shutdown and storage section.
NG
WARNI
!
Components must be lifted using correct lifting tools (such as a forklift truck, a crane) and tackle
with a load capacity greater than the weight of the component stated in the section below.
Use shackles when liftning components.
Any complementary lifting instructions must be followed.
Components must be empty when lifted.
The AOT reactor, filter, CIP and control cabinet must be lifted according to the instructions
in the following sections.
6 AOT Lift
10.2.2 Filter
The illustration shows a Hydac filter, but the principle and values apply for the Filtrex filter.
Weight of filter (empty with adaptor plates on flanges): 1020 kg. L=95 cm.
6 FilterLift
10.2.4 Cabinets
Use intended lifting attachment at the top of the cabinet.
6 CabinetLift
Control cabinet
Weight: 55 kg.
Center of gravity: A=55 cm. B=30 cm.
Protect the control panel screen when lifting the control cabinet.
LDC
Weight: 440 kg.
Center of gravity: A=105 cm. B=55 cm.
2 Maintenance schedule 9
2.1 Calibration schedule 11
2.2 Recommended spare parts on board 13
2.3 Serial number information 13
2.3.1 Indicating serial number 13
2.3.2 Example 14
4 AOT reactor 23
4.1 Safety information 23
4.2 Replace UV lamp and quartz sleeve 25
4.2.1 Disassemble UV lamp 25
4.2.2 Disassemble quartz sleeve 28
4.2.3 Assemble quartz sleeve 28
4.2.4 Check for leaks after quartz sleeve assembly 29
4.2.5 Assemble UV lamp 29
3
4.3 Internal inspection of AOT reactor 30
4.4 Dismount and mount lamp power
supply (LPS) 31
4.5 Test LPS installation 33
5 Filter 35
5.1 Remove filter cover and filter element 36
5.2 Mount filter element and filter cover 38
5.3 Clean filter element and pre-filter 38
6 CIP module 41
6.1 Change and refill CIP liquid 41
6.1.1 Change CIP liquid 43
6.1.2 Refill CIP liquid 43
7 Flow meter 51
7.1 Mount flow transmitter 51
7.2 Change direction of flow transmitter 53
7.3 Change direction of flow transmitter
control pad 54
7.4 Clean flow meter electrodes 56
8 Valve actuator 57
8.1 Preparations and conditions 58
8.1.1 Tightening torques for actuators 58
4
8.2 Dismount actuator 59
8.3 Mount actuator on valve 59
8.4 Change direction of actuator without
position sensor (V40436, V3204 and
V3212) 61
8.5 Change direction of actuator with
switch box (V2013, V2019, V20132,
V21231 and V40335) 62
8.6 Change direction of actuator with
position sensor (201-19 and 20120) 62
8.7 Change direction of actuator with
positioner (2018) 64
8.8 Mount pilot valve on actuator 64
8.9 Adjust valve end position 65
8.10 Adjust valve traveling speed 66
8.11 Calibrate positioner on V201-8 68
8.12 Adjust cam position on V201-8 70
9 Ball valve 71
9.1 Replace seals in ball valve 71
10 Level switch 73
10.1 Mount level switch 73
10.2 Dismount level switch 74
10.3 Test level switch 74
12 Control panel 77
12.1 Clean control panel 77
12.2 Replace control panel 77
5
14 Control cabinet and lamp drive
cabinet (LDC) 81
1 Introduction
This chapter contains information and instructions about how to service the PureBallast system.
Instructions are sorted per component. The chapter is opened with a maintenance schedule
covering checks and services that must be performed with specified intervals.
NGE R
! DA
Before maintaining the PureBallast system, the power supply must be switched off, to avoid
accidental starts. See instruction Abort operation and deactivate the system in chapter 3.
Operating instructions and control system description.
NOTE
All maintenance and calibration activities must be recorded in the vessels maintenance log.
This is required by the ballast water convention. It is therefore recommended that the activities
in the maintenance and callibration schedules below are entered in the vessels general
maintenance system.
Always read and follow the documentation that are included in shipment of components and
spare parts regarding handling, safety and disposal.
Before maintaining the PureBallast system, the following valves must be locked in closed
position: V201-3, V201-9, and V201-8. See instruction Lock valve in closed position on page 20.
Follow local regulations for electrical installation and grounding (earthing).
Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
Point of contact: To order service or spare parts, contact your local Alfa Laval office. For
more information, see www.alfalaval.com.
Follow this maintenance schedule to secure performance, safety and durability of the system and
its components. The schedule is sorted per component. The table refers to instructions usable
when performing the respective action.
AOT reactor Outer inspection Once a year. If necessary, See Spare parts
of seals for change according catalogue for
leakage. to Open AOT service kit.
reactor.
CIP liquid pH value check. Every 3rd months, See Change CIP
whichever comes liquid or Refill CIP
first. liquid.
CIP liquid level Rule of thumb: See Change CIP If the CIP liquid
check. Once every 3 liquid or Refill CIP level is low but the
months. liquid. pH value is below
Depending 3, CIP liquid and
on number of water can be added
AOT reactor to fill up the liquid
and ballasting level in the tank.
frequency, the liquid Note: pH value
check might have to must be checked
be performed more afterwards to
regularly. secure correct pH
value.
Control opening Once a year. See chapter 7. Open and close the
and closing end Service manual, valves and inspect
stops. section Valve visually.
actuator for
instructions.
1. Connect a calibrated portable ultrasonic flow meter close to the flow meter.
2. Establish flow in the system.
3. Compare value indicated in control system and measure equipment.
Pressure 3. Compare values indicated for the three transmitters in control system
transmitter and measure equipment.
(PT201-16)
4. Open 403-35 from the control system, and compare again.
Pressure gauge PT201-16
(PI201-18)
5. Open V403-35 to apply pressure to the system.
6. Adjust handle on PT201-16 to establish pressure to measure point.
7. Compare value indicated in control system and measure equipment.
PI201-18
AOT reactor 1. Depressurize and drain the reactor: Remove the drain plug at the bottom
components of the AOT reactor.
TT20133
Temperature
transmitter
2. Dismount the transmitter and place in water with known temperature
(TT201-33)
(calibrated measure instrument).
Temperature 3. Compare value indicated in the control system and measure equipment.
switch (TS201-
60) TS201-60
Temperature Place a calibrated thermometer inside the cabinet and compare after 30
transmitter in minutes.
LDC (TT401)
AOT reactor
CIP module
Filter
Serial numbers shall be used at error reporting and other contacts where a specific component is
discussed.
Serial number for the complete PureBallast system. See label on the side of the control cabinet.
Serial number for the component in question. If the component is installed on, or in, another
component, the number for the mother component shall be stated.
Item number for the component. The item number identifies a unique component in the system.
It begins with a letter abbreviation indicating the component type, for example: LS (level switch),
P (pump) and PI (pressure gauge). A complete list of abbreviations is found in chapter 6.
Installation description and drawings, section Connection list.
2.3.2 Example
If the level switch is faulty, the following information shall be stated:
AOT reactor
7 AOT Snr
Filter
7 FilterSnr Filtrex
NOTE
7 LDC sernr
NOTE
Flow meter
NOTE
7 FM snr 576179_manual 2
This section covers instructions on how to open, close and lock/unlock valves manually.
Avoid operating valves manually. Valves are normally operated from page 1.1 Overview in
the control system (manual mode). See chapter 3. Operating instructions and control system
description for instruction.
1. Identify which button (illustrated on page 47) on the valve block that controls the valve. The
lower button operates the inner hose under the valve block, and vice versa. Also see the
sticker under the valve block.
2. Press the button on the valve body with a screw driver to operate the valve.
Position 0 Closed (default position). If the position screw is in position 0 and the valve is
closed, it can be manually opened. But if the position screw is in position 0 and
the valve is opened, it cannot be manually closed.
Position 1 Opened.
1. If there is limited access to the screw, it is possible to remove the DIN connector.
4. When done, turn back the screw to position 0. If the DIN connector was removed, connect it
again.
Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
Follow the steps below
1. Set the valve to closed position from the control system. Control the position indicator, to make
sure. The yellow position indicator is in line with the valve throttle (indicating open when
the position indicator is in line with the pipe).
2. Disconnect power and instrument air. Verify that the valve is not under pressure.
3. Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
4. Measure exactly how far out the end stop bolt (4) is from a reference surface, for example the
actuator house. Make a note of the distance. This information is needed when unlocking
the valve.
5. Open the locking bolt (3) and turn them a couple of turns.
6. Screw the end stop bolt (4) to its bottom position and tighten the locking bolt.
8. Slide the safety cover over the end bolts and lock the safety cover with the pad lock.
Note that the end positions of the end stop bolts are factory adjusted and must not be readjusted.
Follow the steps below
1. Disconnect all power and instrument air. Verify that the valve is not under pressure.
2. Open the padlock (2) on the actuator and remove the safety cover (1) from the bolts (3, 4).
7 576075_lock_manual
4. Adjust the end stop bolt (4) to the same position (distance from reference surface) as before
locking the valve, according to the notes made during locking.
NOTE
It is important to adjust the ends stop bolt to the correct position. Otherwise the actuator
may be damaged.
5. Tighten the locking bolt (3).
7. Slide the safety cover in position over the end stop bolts. Lock the safety cover with the pad
lock.
NGE R
! DA
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Always lock valve V2019, V2013 and V2018 if you open the AOT reactor in some way.
See Lock valve in closed position on page .
UV lamps radiate ultraviolet radiation when lit. Only operate the UV lamp when correctly
installed inside the AOT reactor with end caps properly closed.
Never dismount or handle UV lamps before they are completely cooled down. A hot UV lamp is
under high internal pressure, and the risk of bursting exists. A hot lamp could also cause a
burn if it is touched.
Before installation, check that the UV lamps and quartz sleeves are not broken.
UV lamps and quartz sleeves are fragile and can easily become damaged. Exercise great care
when handling them. Do not apply vibrations or shock to the UV lamp. This can cause breakage
and shorten lamp life. Broken glass/quartz can also cause severe cuts. Always use protective
eye glasses and clean cotton gloves when handling UV lamps and quartz glass sleeves.
NGE R
! DA
UV lamps contain a small amount of mercury (less than 0.2 grams per lamp) and must be
handled and disposed of with care. Used lamps UV can be handled and disposed of in the same
way as fluorescent lamps. Please refer to national regulations. If a UV lamp has accidentally
been broken, mercury could be spilt. Remove mercury with a special tool such as a syringe
(or use pure sulphure to bind the mercury for easy collection).
Do not allow mercury to come in contact with your eyes or skin. Do not inhale mercury fumes.
Free mercury must be kept in an airtight bottle, and must be disposed of according to
national regulations.
In case of having inhaled mercury fumes, consult a doctor and follow medical instructions.
7 AOTexploded2
1. Cap
2. Cap nut
3. Bush
4. O-ring (inside bush)
5. Cable connector
6. Allen screw
7. Glass socket
8. O-ring
9. UV lamp
10. Quartz sleeve
The PureBallast system must be turned off, and the power disconnected.
After UV lamps have been changed, the runtime must be reset in page control system page 4.4
Operation timers AOT 13. Requires login level Advanced operator.
Wait at least 10 minutes after completed ballast or deballast process, to allow the AOT reactor
to cool down to ambient temperature. If the UV lamps are hot they are under internal positive
pressure and may burst if broken.
NG
WARNI
!
The AOT reactor must not be under pressure when dismounting the UV lamps.
NG
WARNI
!
Burn hazard: UV lamps can be hot and cause burns.
Follow the steps below
1. Unscrew the cap nuts (2) holding the caps (1). There is one nut on each side of the AOT reactor
per UV lamp. If required, use a screwdriver on the nut, gently tapping with a hammer to release.
2. Carefully disconnect the two cable connectors (5) in both ends of the UV lamp (9).
7UVlampConnection
Carefully draw out the UV lamp (3) with the electric cable, by holding the electric cables in
both ends. When pulled out, only hold the UV lamp by the ceramic ends. Immediately after
removal, place the lamp in its protective cover.
If required, use a screwdriver to press on the ceramic end of the lamp inside the bush on the
other side while carefully pulling the electric cable at the other end.
7UVBushScrewdriver
5. If the quartz sleeves is not broken, mount the new UV lamp according to the instruction
Assemble UV lamp on page 29. If broken see the Preparations and conditions section above.
NG
WARNI
!
Hot water may escape from the AOT reactor when removing the drain plug.
Follow the steps below
1. Close the AOT reactor inlet (V201-19.n) and outlet (V201-20.n) valves from the control system
set in manual mode.
2. Depressurize and drain the AOT reactor: Remove the drain plug at the bottom of the AOT
reactor.
4. Disassemble the UV lamp according to the instruction Disassemble UV lamp on page 25.
5. Loosen the three Allen screws (6) of the glass socket (7) on both sides; just a few turns to
release them.
6. Unscrew the Allen screws completely at one side. Carefully remove the glass socket, to avoid
breaking the quartz sleeve. Then remove the glass socket on the other side.
7. Remove the O-rings (8) on both sides. The O-rings are firmly stuck in their seat, and will be
damaged during removal, but shall be replaced at assembly. Use an angled or hooked O-ring
tool to loosen and remove the O-ring. Be careful to avoid to break the glass.
If the O-ring is hard to remove, try the following:
Moisten the O-ring with acetone or denatured alcohol.
Loose the O-ring in a couple of places before removing it.
Perforate the O-ring to get a good grip.
9. Carefully clean the surface and remove any small parts, for example glass or rubber.
2. Wet the O-rings (8) with water and slip them over respective side of the quartz sleeve.
Check that the O-ring are positioned evenly on both sides. If not, they may be damaged
and cause leaks.
The O-rings shall not be pressed into position, the glass socket will press them into position
when fastened later.
3. Carefully mount the first glass socket on the quartz sleeve with three Allen screws evenly, but
do not tighten the screws. Note that the waxed screws must be used to avoid seizing.
7QuartzSleeve
4. Once the Allen screws (6) are evenly entered, carefully tighten them evenly to a torque of 7 Nm.
7. Follow the instruction Check for leaks after quartz sleeve assembly.
1. Pressurize the AOT reactor with water to between 2 and 4 bar (0.2 and 0.4 MPa).
A leakage check must have been performed according to the instruction Check for leaks after
quartz sleeve assembly.
Use waxed screws.
New heat resistant O-rings must be used in the two bushes. Always replace used O-rings.
Keep the UV lamp in its protective cover as long as possible. Do not touch the glass of the
lamp; hold the lamp by its ceramic end parts.
Glass sockets and bushes must be dry and clean before mounting.
After UV lamps hav e been changed, the runtime must be reset in control system page 4.4
Operation timers AOTs.
Follow the steps below
1. Mount the new heat resistent O-rings in the two lamp bushes (3).
4. Insert the other bush in the opposite side of the AOT reactor.
5. Make sure that the connection is clean to ensure good electric connection (no rust, burning or
fading on the connectors). Reconnect the two cable connectors for the UV lamp.
7UVlampConnection
6. Mount the UV lamp caps and tighten the cap nut at both ends of the UV lamp, by hand only.
Make sure that the electric cable is is not squeezed between the cap and the bush when the
cap is mounted. Slack can be pushed into the bush.
7. Re-fit the drain plugs at the bottom of the AOT reactor and/or at the flanges under the AOT
reactor.
8. Control the control system page 3.1 Alarm list, to make sure there is no alarm when after
the the lamp power supply is on.
The AOT reactor must be depressurized and the AOT reactor must be emptied from water.
7 OpenAOT
1. Access hatch
2. Inspect the bottom of the AOT reactor to see if there are any dirt or larger particles. If so,
remove.
Note: Be careful not to break the quartz sleeves.
NG
WARNI
!
Switch off the main breaker on the LDC door. The LPS has high voltage/power (600 V)
inside and on the lamp power connector, even when UV lamps are not lit.
The LDC contains a fan, which can cause injury if in operation.
Follow the steps below
7 LPSmaint
1. Dismount LPS
Release two power connectors at the bottom of the LPS and the signal cable connector
at the top.
2. Loosen the nuts at the bottom (1) and the top (2) of the two rods holding the LPS. If necessary,
loosen nuts for adjacent LPS.
NOTE
Make sure not to drop the washer into the LPS. It may cause short circuit.
4. Mount LPS
Set the DIP switches on the LPS according to chapter 4. Parameters, section Lamp power
supply (LPS) parameters.
6. Reconnect the three connectors. Make sure the connectors sit tight.
9. Switch on the main breaker on the LDC door and check that both LPS:s function correctly
according to instruction Test LPS installation below.
NG
WARNI
!
This instruction must be performed after cable connection. If not hazardous situation may arise
which, if not avoided, will result in death or serious injury.
DANGER
!
Before operating the AOT reactor, make sure that there is water in the AOT reactor.
Follow the steps below
2. Check that there is water in the AOT reactor(s) (LS201-29). Check the LED on the level switch:
Steady yellow light indicates that there is water in the AOT reactor.
3. Switch on the main breaker on the LDC door. Switch on the power to the AOT reactor using
the switches on the breaker cabinet(s).
4. Start UV lamps one by one from the control system (set to manual mode). Make sure that the
UV lamps are lit. This is checked in the AOT reactor popup and on the LPS.
Note: It can take up to 90 seconds for the lamp to start.
5. Check LEDs on the LPS and the alarm list in the control system. Make sure that no alarms
have been triggered by the LPS.
Disconnect the power to the filter, using the main switch on the control cabinet.
Always lock valve V2019, V2013 and V2018 if you open the filter in some way. See Lock
valve in closed position on page .
Only perform maintenance and servicing work when the filter is cooled, depressurized and
drained.
Shut off the air supply to the filter.
Visually inspect seals during maintenance. Replace if necessary.
The person performing this procedure must have knowledge about the specific standard used to
eliminate the risk of explosion, for example IEC 60079 series.
Lifting device is needed for this instruction.
Filter cover and element weight (kg): 285.
7 FiltrexService
1. Filter motor
2. Filter motor bolts
3. Cover bolts
4. Lifting lugs
1. Close the following valves: V201-3, V201-32, and V310-2 according to the instruction in
the Operate valves manually on page 19.
3. Remove the motor. Be careful not to harm the motor fitting when lifting it from its seat.
4. Remove the cover bolts (3) and the lifting lugs (4).
5. Screw two filter cover bolts in the lifting lugs holes until the cover raises slightly from the filter
house.
6. Remove the cover bolts and fasten the lifting lugs in their holes again.
7. Fasten a lifting device in the lifting lugs and lift the filter cover with the filter element carefully
out of the filter.
Note: The filter should be lifted in one continuous movement, without sudden jerks even if
the filter element is slightly stuck in the filter house.
9. Remove bolts to the bottom shaft support that holds the shaft inside the element. Remove it
carefully.
10. Remove the seeger ring (A) from the backflush shaft.
7 FiltrexSeeger
11. Pull out the shaft. If it is stuck, give a couple of light blows with a wooden hammer on the top
of the shaft to release it.
13. Unscrew the four Allen screws (B) inside the element to loosen the cover.
7 FiltrexCoverScrew
15. Lift the pre-filter from the bottom of the filter house.
Note:
Clean the upper inside of the house at the top of the. The area where the O rings meet the
housing should be clean.
No force should be used to fit the filter element in the filter house or to fit the motor in its seat.
Check the O rings. Replace if necessary.
Fill up the filter with fresh water after it is mounted.
There is not need to de-air the filter when it is filled up.
5.3 Clean filter element and pre-filter
Follow this instruction to clean the filter element. At the same time, check that the filter element
is in good condition.
Alpacon descalant offshore may be used as cleaning agent. See Safety data sheet / CIP liquid
in chapter 6. Installation description and drawings.
Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant to 20 parts
fresh water. Follow this mixing ratio, regardless of recommendation on label.
Alpacon descalant offshore storage temperature: 0 C to +55 C.
NG
WARNI
!
Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves and goggles.
Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
NG
WARNI
!
If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
The pH value should be approximately 2.0.
Please proceed with the utmost caution when transporting, assembling, disassembling and
cleaning the filter element.
Follow the steps below
1. Follow the instructions Remove filter element (page 36) to remove the filter element.
3. Soak the filter element in the cleaning agent and leave it to soak for 13 hours. Let the element
dip dry before next step.
5. Place the element in so it does not fall over when cleaning it.
6. Spray the filter element with water (6080 C) using a flat nozzle from the outside. Note: If a
high-pressure cleaner is used, the pressure must not exceed a maximum of 15 bar. If a cleaner
with higher capacity is used, compensate by increasing the distance, minimum 30 cm.
7. Blow the filter element with instrument air (with 10 micron filter or finer), from the outside.
8. Inspect the filter element from the outside with a magnifier to make sure that it is clean. If
needed, repeat the procedure. This time it is enough to let the element soak for 5 minutes.
ON
CAUTI
!
Risk for eye and skin irritation. Avoid contact with eyes and wear protective gloves and goggles.
Follow rules when handling CIP liquid agent, regarding ventilation, personal protection etc.
ON
CAUTI
!
If Alpacon descalant offshore comes in contact with eyes or skin, rinse thoroughly with cold
water.
Max tightening torque for bolts on flanges: 20 Nm.
The instructions requires pH test equipment (paper indicator or pH meter). This is not a part of
Alfa Lavals scope of supply.
The pH value should be between 2.0 and 3.0. From the beginning, the pH value is approximately
2.0. When the pH value rises to 3.0 the cleaning liquid must be changed.
Mixing ratio for Alpacon descalant offshore is 1 part concentrated Alpacon descalant offshore to
20 parts fresh water. Follow this mixing ratio, regardless of recommendation on label.
The CIP tank shall be filled with maximum 250 liters. Min and max filling of CIP liquid can
be read on the CIP tank.
Alpacon descalant offshore storage temperature: 0 C to +55 C.
Used CIP liquid may contain residues from the cleaning process that can potentially have an
impact on the environment, although this impact is regarded as very small. There are no
transport restrictions.
Used CIP liquid is drained to one of the following: drain tank or sludge tank. Do not drain to
bilge. Handle according to local regulations.
When performing these routines, consider the need for service kits. See Spare parts catalogue.
7 CIP
CIP module
1. If the drain valve (3) is connected to bilge (or other) tank, follow the sub steps below.
Otherwise, go to step 2.
a. Open the manual drain valve V460-3 under the CIP tank.
b. Wait for the tank to be totally drained. Then close the drain valve.
2. If the drain valve is not connected to the bilge tank, the steps below can be followed. This
operation requires login level Advanced operator or higher.
a. Open valves V320-2 and V460-2 from the control valve, and V23011 manually. Start
pump P321-5 (3) and P320-1 (4).
b. Wait for the tank to be totally drained. Then stop the pumps and close the valves in
reversed order. Go to step 3.
3. Open the cap (1) on top of the CIP tank and pour 12 liters of CIP cleaning agent into the tank.
4. Fill the tank with fresh water to the Max indication on the tank, approximately 240 liters.
5. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is too high, add more CIP cleaning agent. Measure again.
6. Go to control system page 4.3 Operation timers. Make a note of the number of AOT reactors
that has been CIPed since last time the CIP liquid was changed. Press the Reset button for
Total number CIP:ed reactors. Requires login level Advanced operator. If this is done each
time the CIP liquid is changed, it is possible to build up experience on how many AOT reactors
it is possible to CIP before it is time to change CIP liquid.
1. Measure the pH value in the tank. Based on the pH value, estimation must be done regarding
the proportions between Alpacon descalant offshore and water. Note that the mixing ratio is
stated under Preparations and conditions above.
2. Mix the cleaning agent with water separately. The result will get better than if mixed mix in
the tank.
3. Pour the mixed CIP liquid into the tank. Do not fill over Max indication on the tank.
4. Measure the pH value in the tank to secure that it is approximately 2.0. If not, adjust the
proportions: If the pH value is still too high, the CIP liquid must be changed. See the Change
CIP liquid instruction in this chapter.
ON
CAUTI
!
Always wear protective eye glasses and gloves while working on the pump.
NG
WARNI
!
Always disconnect the PureBallast system from the power supply before disassembling, and
secure it from being switched on.
Before disassembling the pump, the pneumatic hoses must be disconnected, and the extension
pipe must be removed and blocked.
Drain the pump from liquids.
The pump should be placed horizontally on a work bench.
7 CIP pump
1. Remove the CIP pump from the CIP module and place it on a work bench.
3. Place the pump on the side that still has the nuts (the pump lays on the nuts) on a stable ground.
5. Carefully lift up the suction and discharge connections (13). You have the centre block (12)
and one of the housings with pin screws (14) left.
6. Upend the pump and carefully pull out the pin screws (14). Be careful not to damage the
diaphragms (15).
1. Put the house wall with the flat side down on a plane surface.
4. Place one of the pin screws on the inside (behind) the valve ball stopper on the lower valve
seat (21). Carefully pull out the valve seat in the housing.
5. Remove the valve ball (23) from the valve seat, buy using a pin screw: Press out the valve ball
stopper (22), which will release the valve ball.
Have backup spares of the sealing (36) and backup O-ring (47). There is a risk that these parts
get damaged during this operation.
Follow the steps below
1. Press the diaphragms (15) to their neutral position (both have the same distance to the
centre block).
2. Hold one of the diaphragms (15) and unscrew the other. Then pull out the remaining diaphragm
with the diaphragm shaft (16).
3. Disassemble the circlips (27) which keep the air valve (61) on its place.
4. Press out the air valve. A wood shaft of a hammer can be used. Be careful not to damage the
sealing edges towards the diaphragm or the air valve.
5. If the shaft sealings (36) seem to be worn out, carefully remove them with a pointed tool.
2. Apply some soft soap solution on the air valve O-rings (30).
3. Push the air valve (61) into the housing. Make sure that the O-rings (30) remain in the right
position. Put the circlip (27) on the other side.
4. Put the diaphragm (15) with shaft (16) into the centre block. Screw the next diaphragm (15)
onto the shaft (16) and fix the holes.
1. Make sure that the O-rings (18) are placed on the in/outlet (13) before assembling of pump.
3. Make sure all pin screws (14) have one nut (37) and one washer (38) each. Nut should only be
put on one or two threads.
4. Put all the pin screws through the housing and then turn the housing so it rests on the nuts.
5. Put the centre block (12) to the housing with screws through the centre block. Be careful not to
damage the diaphragms.
6. Place suction and discharge connections (13) in their positions in the housing. Be careful not
to damage the O-rings (18).
7. Put the second housing (11) onto the pin screws (14). Make sure that suction/discharge
connections are in right direction. Be careful with the O-rings.
8. Fasten the nuts (37) crosswise by hand, with or without washers depending on how much of
the thread comes out. Turn the nuts gently with a tool to close the pump. If some of the nuts
were fastened without washer, unscrew those and put washers underneath. After a few weeks
operation a follow up draft of the nuts is recommended.
1. Open valves V320-2 and V460-2 from the control system, and V23011 manually. Start
pump P321-5 (4) and P320-1 (4).
2. Observe if the motors sound and functions OK. If not, check installation and connections and
attend to and test again.
The valve bodies does not have individual placing, they can be placed in any order.
DANGER
!
Always disconnect the PureBallast system from the power and air supply before disassembling,
and secure it from being switched on.
7 Valve block
Valve block
1. Remove the scresw holding the valve bodies (2) and the signal plate (4).
4. Attach a new sealing on the new valve body and fasten the valve body to the valve block.
2. Attach the cables according to electrical drawing Control cabinet / interconnection diagram in
chapter 6. Installation description and drawings.
2. Operate the service air according to instruction Open and close valves manually (CIP valves)
on page 19 to blow out the dust.
1. Connect the hoses according to the signal plate (4) on the valve block.
Flow sensor: A pipe with four electrodes detecting the flow. On top of the pipe, there is a
terminal box, where the flow transmitter is mounted.
Flow transmitter: Monitors and transmits information to the PureBallast control system. The
flow transmitter is also used to set parameters for the flow meter. A Sensorprom in the flow
transmitter contains the data.
If the flow meter is replaced, settings must be checked according to chapter 4. Parameters,
section Flow transmitter parameters.
See chapter 6. Installation description and drawings, section Control cabinet / Interconnection
diagram for detailed information.
It is recommend that a shielded power cable is used.
NG
WARNI
!
Potential hazards / Grounding: The mains protective grounding wire must be connected to the
terminals in accordance with the diagram (class 1 power supply).
Follow the steps below
1. Remove and discard the lid from the terminal box on the flow sensor.
7 FM Lid
2. Fit PG13.5 cable gland for the power and signal cable.
3. Connect power and grounding to the following terminal positions marked on the circuit board:
1=+
2=
Grounding.
4. Connect current output signals to the following terminal positions marked on the circuit board:
31 = +
32 =
6. Mount the flow transmitter on the terminal box using the two screws. If other direction of the
flow transmitter is desired, please follow the instruction Change direction of flow transmitter on
page 53.
7 FM MountTM
7 FM MountTM
2. Disconnect the power supply (terminal positions 1, 2 and grounding) and output signal cables
(terminal positions 31 and 32) from the circuit board.
3. Remove the coil plug (1) from terminal positions 85 and 86. Remove the plug (2) from terminal
positions 82, 0 and 83.
4. Unscrew the two screws (indicated below) holding the circuit board to the terminal box and lift
up the circuit board.
Note that the sensorprom is mounted on the underside of circuit board; be careful not to loose
it. Sometimes, the sensorprom remains in its seat on the terminal box.
7 FM ScrewCricuit
5. Disconnect the grounding wire holding the circuit board to the terminal box.
If the flow transmitter shall be turned 180: Move the sensorprom (1 in the illustration
below) to the position on the opposite side of the circuit board and refit in reversed order.
If the flow transmitter shall be turned 90: Continue with next step.
6. Unscrew the four screws (2) on the terminal box to loosen it from the flow sensor.
7 FM LooseTB
7. Turn the terminal box to 90 and fasten it with the four screws.
7 FM LoosFrame
7 FMScrewPad
7 FM TurnPad
7 FMScrewPad
5. Snap-lock (a click is heard) the outer frame onto the control pad.
7 FM FastCover
It is important that the electrodes are clean to secure accurate output. If the four electrodes in the
flow sensor get dirty, it may result in inaccurate and varying output.
2. Close the main valves connecting the PureBallast pipe net to the vessels ballast pipe net and
secure it from being switched on. See instruction Lock valve in closed position on page 20.
3. Remove all the flange bolts on the flow meter, except one on each flange. Note that the
remaining bolts on each side must be in the same position on respective flange.
4. Loosen the nuts on the remaining bolts. Swing the flow meter outside the pipe.
Valve actuator with switch box for position feedback to control system
1. Switch box
2. Bracket
3. Actuator
4. Pilote valve
5. Bracket - Used for valves with dimension 400
6. Coupling with position indicator - Used for valves
with dimension 400
7. DIN connector
8. Position indicator
7 Actuator
1. Safety cover
2. Pad lock
3. Lower position for indicator screw
4. Upper position for indicator screw with screw
5. Position indicator
6. Center screw
7. Bracket
8. Puck
9. Locking bolt
10. End stop bolt.
M5 0506
M6 1011
M8 2325
M10 4852
M12 8286
M14 132138
M16 200210
M20 390410
1. Remove the DIN connector to disconnect the power. Let the air connection remain.
Result: Valve goes to closed position (due to the air connection). The yellow indicators on the
puck shows position of valve: closed. The yellow position indicators are in line with the valve
throttle (indicating closed when the position indicators are in opposite line with the pipe).
2. Disconnect the air hose to the pilot valve. Verify that the actuator is not pressurized. Always
use caution and double-check that ports 2 and 4 are vented and are free from any accessory
and/or device.
3. If the actuator have a switch box at the top: Loosen the four screws holding the switch box to
the actuator. Remove the switch box together with its bracket.
4. Loosen the four hexagonal screws holding the actuator to the valve.
5. If the actuator is mounted on the valve with a bracket and coupling (dimension 400): Loosen
the screws holding the bracket to the valve. Make sure not to loose the coupling between the
valve and actuator when lifting the actuator.
ON
CAUTI
!
The actuator must not be pressurized at any time during installation as it may result in injury.
The valve must be in closed position.
The valve position must not be adjusted during the routine.
The utmost cleanliness is required during air supply connection to the actuator, that is, the
connecting pipe thread, fittings and seals must be clean and dirt-free.
Before fitting onto the valve, make sure the actuator/valve is correctly orientated, depending on
which direction of rotation is required.
Follow the steps below
1. Note the position of the groove (2) of the valve stem (3). It indicates the position of the valve
throttle. The illustration shows a square variant, but octagonal versions exist.
7 ValveStem
2. Make sure that the lock pin (inside the valve stem) only travels in the allowed sector (1) and
that it does not pass the opening (5).
3. If the actuator is mounted on the valve with a bracket and coupling (dimension 400): First fit
the coupling on the valve stem. Make sure that the red position indicator on the coupling is in
line with the pipe when the valve is open.
4. Fit the actuator onto the valve stem (or the coupling). The actuator may only be positioned in
even 90 intervals in relation to the valve. It is not allowed to adjust the position by turning the
actuator by hand after it is fitted on the valve stem.
5. Mount the actuator on the valve with the four hexagonal screws. For each screw, one washer
and one spring washer shall be used. Tighten with torque according to the table Tightening
torques for actuators on page 58.
6. If the actuator have a switch box at the top: Make sure that the yellow position indicator under
the switch box is in line with the throttle (according to the groove in the valve stem). The yellow
position indicator shall be in line with the valve throttle (indicating open when the position
indicator is in line with the pipe). If not, remove the position indicator, turn it 90 and refit it.
Mount the switch box with the bracket on the actuator, using the four bolts.
8. Operate the valve to make sure it operates in the desired direction of rotation.
3. Note the position of the groove of the valve stem. It indicates the position of the valve throttle.
5. Unscrew the center screw (4) holding the puck (6) and a bracket (5).
7 ActDirectWithout
6. Lift the puck (6), rotate it 90 and fasten it with the center screw (4) and bracket (5).
7. Make sure that the yellow position indicators (3) is in line with the throttle (according to the
groove in the valve stem). The yellow position indicators shall be in line with the valve throttle
(indicating open when the position indicator is in line with the pipe). If not, remove the position
indicators, turn them 90 and refit.
3. Before mounting the switch box, change the position of the yellow position indicator, so it
is in line with the throttle.
This instruction is valid for the following valves: V201-19 and V201-20 on the AOT reactor.
1. Dismount the actuator from the valve according to instruction Dismount actuator on page 59.
Put the actuator on a work bench.
2. Disconnect the DIN connector (2) from the coil: First loosen the screw (1), and then pull up
the connector.
7 DisconDINcon
3. Unscrew the center screw (6) holding the puck (8) and a bracket (7).
7 DirActPosSnsr
4. Lift the puck (8), rotate it 90 so that one position indicator (5) with a screw is in contact with the
position sensor. Fasten the puck with the center screw (6) and bracket (7).
5. Move the screw on yellow position indicator to the top position and move the screw on black
position indicator to the bottom position.
6. Make sure that the position sensor have a maximum distance of 1 mm from the puck (7). The
position sensor and the position indicator screws must be close to give a signal. If not, loosen
the screws and adjust the position. Tighten the screws to fixate the position.
7. Fit the actuator onto the valve stem in its new position according to instruction Mount actuator
on valve on page 59.
8. Make sure that the yellow indicator (5) in line with the valve throttle according to the groove in
the valve stem.
11. Check that the installation is OK, by making sure that the A1 LED is lit on the position sensor
(visible from the side).
1. Dismount the actuator from the valve according to instruction Dismount actuator on page 59.
2. Fit the actuator onto the valve stem in its new position and mount it on the valve with the four
hexagonal screws. For each screw, one washer and one spring washer shall be used. Tighten
with torque according to the table Tightening torques for actuators on page 58.
3. The position indicator scale shall be correct, but make sure that the scale still indicates correct
opening percent according to the valve throttle position. If not, loosen the four bolts to the
bracket holding the switch box. Lift it and turn the scale so it is correct.
4. Refit the switch box. Make sure that the peg on the scale fits to the carrier on the puck
mounted on the actuator.
7 MountPilote
1. Check that the O-rings are fitted on the pilot valve, on the side facing the actuator.
2. Fit the pilot valve on in the actuator, so that the pin on the actuator fits the hole on the pilot
valve. The throttle valves (2 and 4) shall be directed downwards.
3. Mount the pilot valve with two Allen screws in the holes (1).
5. Fit the DIN connector (5) on the coil, including gasket. Then fasten the connector with the
screw (6).
7 576075_lock_manual
1. Note the exact position of the position indicator for reference after adjustment.
2. Open the padlock (2) on the actuator and remove the safety cover (1).
Result: Two sets of bolts are displayed. The right set adjusts closing position and the left
set adjusts open position.
4. Adjust end position by turning the end stop blot (4) with small turns.
Clockwise decrease the end position.
Counterclockwise increase the end position.
NOTE
6. Tighten the locking bolt (3) to fixate the position of the end stop bolt (4).
7 AdjustTravel
1. Operate the valve manually to check traveling speed according to the instruction in the Operate
valves manually on page 19.
7 201-8Positioner4
7 201-8Positioner
1. Make sure that the transmission ratio selector (6) is set to 90 according to sticker on the
component. If not: Adjust by pressing the bar with a screw driver.
2. Make sure that the Arrestor device wheel (1) is set to 90. If not: Adjust by turning.
3. Make sure that Menu 1 is displyaed. If not: Press HAND button repeatedly until it is.
Make sure that turn is displayed in the menu. If not: press + or repeatedly until it is.
7 201-8Positioner2
- Use a screw driver to loosen the yellow locking wheel (counter clockwise).
- Turn the adjustment wheel (5) by hand until a 0 is displayed between the d and the U as
shown in the illustration. Normally this is when the value in the screen is close to 0.
7 201-8Positioner3
9. Press the hand button for 5 seconds until a number or VER is displayed, then let go of the
button.
Result: MAN is displayed.
Trouble shooting
- Reset to factory settings: Press hand button repeatedly until menu 50 is displayed.
- Press + button until oCAY is displayed.
- Restart instruction Calibrate positioner on V201-8 from step 3.
Hint: A multimeter can be used to indicate position of the cam wheels, if it is hard to hear the click
from the micro switch, or if it is inconvenient to see valve position in control panel. Connect a
multimeter to connection point 41 and 42 in the positioner.
3. Close it to approximately 10 %.
4. On the positioner: Adjust both cam wheels to same position. Cam wheels are above the
adjustment wheel (5) on page 68.
5. Turn the cam wheels in any direction until it valve indicates steady green in the control panel.
Miltimeter indicate circuit closed.
6. Turn the cam wheel slowly counter clock wise until you hear a click from the micro switch in
the positioner. Stop directly after the click. Stop directly after the multimeter changes to
indicate circuit open.
7. Check that the valve is indicated as open (steady green) in the control panel.
Result 2: Valve indicated as red. Cam wheels are in wrong position, for example due to the
wheels been turned too much after the click). Miltimeter indicate circuit open. Repeat from
step 2 until setting is OK.
7 BallV
32 = 1 2025 Nm 14.3 Nm
inches
2. With the valve in the open position (lever to be parallel to the axis of the pipe), remove all the
body bolts (19) except one.
3. Loosen the nut (20) on the remaining bolt. Swing the body outside the pipe.
5. Replace seals (5, 6, 7, 9, 10, and 24). They are available in a spare parts kit for the ball valve.
6. Mount in reverse order. The body bolts of the valve should be tightened evenly. Tighten
one-side snugly, then the one diagonally across. Repeat for the other bolts, bringing them all
down tightly in sequence. Make sure the maximum tightening torque is observed according
to the table above:
This section contains information about the level switch LS201-29 installed in the AOT reactor. For
information about status indications, see chapter 5. Alarms and faultfinding, section Level switch.
7LS Component
Level switch
NOTE
2. Seal the level switch with lock tight or equivalent pipe seal.
4. Identify the sensor align mark () on the component. Make sure that it is positioned on the
upper side of the level switch.
5. Complete the seal carefully by tightening the component with a spanner. Use the spanner on
the hexagon flats, but not on the level switch body.
The external surface may be hot. Care must be taken to avoid possible burns.
Follow the steps below
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the level switch body.
3. Remove the level switch and remove the old seal from the threads.
1. Make sure that the component i powered (the green LED shall be lit).
2. Hold a magnet to the test point indicated on the on the level switch, indicated below.
7LS Test
3. Make sure the level switch reacts to the magnet. The component is OK if the green and
yellow LED is lit.
This section contains information about the temperature switch TS201-60 and the temperature
transmitter TT20133 installed in the AOT reactor. The two components are similar in design, so
the same instructions can be used.
7 TS and TT
NOTE
1. Seal the components threads using lock tight or equivalent pipe seal.
3. Tighten the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
The external surface may be hot. Care must be taken to avoid possible burns.
Follow the steps below
2. Loosen the component with a spanner. Use the spanner on the hexagon flats, but not on
the components body.
3. Remove the level switch and remove the old seal from the threads.
NOTE
Control panels may only be cleaned when set in wipe mode. This is to prevent unintended
functions from being triggered by buttons pressed during cleaning.
Preparations and conditions
Never use aggressive solvents, chemicals, scouring agents, pressurized air or steam jet.
Follow the steps below
2. Clean the display and surrounding front cover with a soft cloth and mild detergent. Do not
spray detergent directly on the control panel.
This section covers information on how to mount and connect the remote control panel. The remote
control panel is either ordered with a mounting plate (for installations in wall, worktop etc) or an IP
protective back cover (for installation on stand etc).
Remote control panel is mounted according to according to drawing Remote control panel /
Dimension drawing on page on page . Note the clearance area.
Use a 24 VDC power cable with minimum cross section of 0.75 mm2, preferably halogen free
and flexible.
Connect power cable to terminal X1 in remote control panel.
Communication cable (W501) between the remote control panel and control cabinet can be
either Ethernet or fiber. Cable requirements and connection points below:
- Ethernet cable Type: Cat 5e (or better), shielded. Max length: 100 meters. One remote
control panel: From terminal X2 in remote control panel s to terminal X13 in the control
cabinet. Two From terminal X2 in second remote control panel to either switch SW1 in
control cabinet or to switch SW1 in the first remote control panel.
- Fiber cable Type: Multi-mode fiber cable with LC connector. Max length: 500 meters.
From remote control panels switch SW1 to switch SW1 in control cabinet.
See Remote control panel / Circuit diagram on page .
1. Hold down the plastic clip on the top of the terminal block and pivot the block towards you.
7IO1_X025002A
3. Hold down the triangle on the top of the I/O board and loosen the board.
7IO2_X025003A
4. Pull the board straight out (otherwise it can fasten in one of its guides).
7IO3_X025004A
5. Compare the part number of the new I/O board to the old board, to make sure it is correct.
6. If changing more than one board at a time, check with the electrical diagram to ensure that
the boards are mounted in the right places.
7. Mount the new I/O board by pressing it straight into place. Make sure the board is firmly in
place, otherwise it will be impossible to mount the cable terminal.
7IO4_X025005A
8. Remount the terminal block. Make sure the clip on the bottom of the block fastens properly in
place on the axel on the bus holder.
7IO5_X025007A
9. Pivot the terminal block on the axel until the clip on the terminal block top fastens into place in
the I/O board.
7IO6_X025006A
1. Lubricate the inside surfaces of the frame with Roxtec Assembly Gel or equivalent, specially
in the corners.
7 Cable1
4. Peel off layers until you achieve a 0.1-1.0 mm gap between the two module halves when
held against the cable.
7 Cable2
7 Cable3
5. Lubricate all modules thoroughly, both on the inside and the outside surfaces.
7 Cable4
6. Insert the modules from the back of the frame opening. If possible, start with the largest
modules.
7 Cable5
7. Tighten the compression unit firmly to seal the frame. Maximum 10 Nm. A good indication is
when the lubrication is squeezed out between the modules.
7 Cable6
1. Adapt the seal to the cable by removing layers from the halves. The halves may not differ by
more than one layer.
7 LDC gland1
2. Achieve an approximate 0.11 mm gap between the halves when testing against the cable.
There shall be a visual gap.
7 LDC gland2
3. Lubricate thoroughly on the inside surfaces and sparsely on the outside of the seal.
7 LDC gland8
5. Tighten the Allen screws crosswise. The seal will compress and seal the transit.
This check should be performed in LDC, control cabinet, AOT junction box.
1. Turn off power to PureBallast from the vessels switch board, to make it currentless. Where
applicable, turn off power to the individual cabinet.
2. Make a random check of approximately 10 % the cables in different areas of the cabinet.
- Make sure that the cables are fastened with sufficiently tightened screws.
- If one cable is loose, check all cables connected to this component / component of the
same type.
- Note: Be careful not to tighten the screws so that the cables are damaged.